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January 2019

www.designworldonline.com

Our exclusive interview with former Google VP and White House CTO Megan Smith......... p. 162

Leadership

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I’ve been familiar with the concept of digital twins for quite a while, but a recent chat with Siemens’ Eric Kaczor showed me how much this technology is poised to take over what we do in design. Not only will it help through the entire manufacturing process, but the feedback and analysis gained can help designers solve problems more thoroughly. In an industry like packaging, there are ways to better serve customers, who are always pushing for faster production times. You can make your assembly line run faster, but you can only achieve so many efficiencies. Eventually, getting better is going to involve digital innovation across the entire product life cycle. Kaczor highlighted three types of digital twins that his company is focusing on: products, packaging and the actual production processes. “We can create a digital twin of a product. That’s designing the product formulation, keeping track of your formulations, keeping track of the information from your customers and what they’re requiring for their requirements of the product,” he said. But digital twins can also be used on the packaging side. Consumer tastes require constant innovation and changes in packaging, so this is a key area that requires developing and refining new designs. “Some of the major beverage companies recently switched to a different type of can and bottle. Maybe that started from CAD. You can have a perfect representation of that in the digital world for simulations. It’s even to the point of figuring out how a can or a bottle crushes down,” he said. “Instead of actually producing one, use a perfect representation in the digital world. Now you can do all those simulations before you actually manufacture one can or bottle.” Lastly, said Kaczor, is the digital twin of the production process. Consider a customer who brews beer. They have their brewing lines, raw materials being brought in, and they have to fill and label and palletize. He explained that all of that can be set up in a digital twin, so the customer can simulate the whole production line from beginning to end. “They can figure out how things move through their plant, where the bottlenecks are. They can fix those bottlenecks in the digital world before they see they have issues in the real world,” he said. The result of all of this is better performance. Plus, once everything is up and running in that real world, there’s plenty of data to gather — data on all the production processes, how they’re running, the temperatures of the motors, whether there are vibrations, etc. And this, Kaczor said, is another key. “You can analyze these data from one machine, an entire production facility, or multiple facilities. You can even gather data from your actual products as they go out into the field. Think about car manufacturers. In my car, I get an email before something fails,” he said. “On the manufacturing floor, we’re collecting data about the real product and the real production. And if you can analyze that, you can make business decisions on how to bring all that insight back to the beginning of the design process.” DW Paul J. Heney - VP, Editorial Director pheney@wtwhmedia.com On Twitter @ DW—Editor

4 January 2019 www.designworldonline.com DESIGN WORLD DW Insights 1-19_Vs5.LL.indd 4

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The Truth About Compressed Air! If you think compressed air is too expensive and noisy - read this. The facts will surprise you!

Compare these Blowoffs

There are a variety of ways to blow the water from the bottles shown in the photo below, but which method is best? To decide, we ran a comparison test on the same application using four different blowoff methods: drilled pipe, flat air nozzles, Super Air Knife (each using compressed air as a power source), and a blower supplied air knife (using an electric motor as a power source). Each system consisted of two twelve inch long air knives. The following comparison proves that the EXAIR Super Air Knife is the best choice for your blowoff, cooling or drying application. The goal for each of the blowoff choices was to use the least amount of air possible to get the job done (lowest energy and noise level). The compressed air pressure required was 60 PSIG which provided adequate velocity to blow the water off. The blower used had a ten horsepower motor and was a centrifugal type blower at 18,000 RPM. The table at the bottom of the page summarizes the overall performance. Since your actual part may have an odd configuration, holes or sharp edges, we took sound level measurements in free air (no impinging surface).

Drilled Pipe

Blower Air Knife

This common blowoff is very inexpensive and easy to make. For this test, we used (2) drilled pipes, each with (25) 1/16" diameter holes on 1/2" centers. As shown in the test results below, the drilled pipe performed poorly. The initial cost of the drilled pipe is overshadowed by its high energy use. The holes are easily blocked and the noise level is excessive - both of which violate OSHA requirements. Velocity across the entire length was very inconsistent with spikes of air and numerous dead spots.

The blower proved to be an expensive, noisy option. As noted below, the purchase price is high. Operating cost was considerably lower than the drilled pipe and fl at air nozzle, but was comparable to EXAIR’s Super Air Knife. The large blower with its two 3" (8cm) diameter hoses requires significant mounting space compared to the others. Noise level was high at 90 dBA. There was no option for cycling it on and off to conserve energy like the other blowoffs. Costly bearing and filter maintenance along with downtime were also negative factors.

Flat Air Nozzles

EXAIR Super Air Knife

As shown below, this inexpensive air nozzle was the worst performer. It is available in plastic, aluminum and stainless steel from several manufacturers. The flat air nozzle provides some entrainment, but suff ers from many of the same problems as the drilled pipe. Operating cost and noise level are both high. Some manufacturers off er fl at air nozzles where the holes can be blocked - an OSHA violation. Velocity was inconsistent with spikes of air.

The Super Air Knife did an exceptional job of removing the moisture on one pass due to the uniformity of the laminar airflow. The sound level was extremely low. For this application, energy use was slightly higher than the blower but can be less than the blower if cycling on and off is possible. Safe operation is not an issue since the Super Air Knife can not be dead-ended. Maintenance costs are low since there are no moving parts to wear out.

Facts about Blowers

Energy conscious plants might think a blower to be a better choice due to its slightly lower electrical consumption compared to a compressor. In reality, a blower is an expensive capital expenditure that requires frequent downtime and costly maintenance of filters, belts and bearings. Here are some important facts: Filters must be replaced every one to three months. Belts must be replaced every three to six months. Typical bearing replacement is at least once a year at a cost near $1000. •

Blower bearings wear out quickly due to the high speeds (17-20,000 RPM) required to generate effective airflows.

Poorly designed seals that allow dirt and moisture infi ltration and environments above 125°F decrease the one year bearing life.

Many bearings can not be replaced in the field, resulting in downtime to send the assembly back to the manufacturer.

Blowers take up a lot of space and often produce sound levels that exceed OSHA noise level exposure requirements. Air volume and velocity are often difficult to control since mechanical adjustments are required. To discuss an application, contact: EXAIR Corporation 11510 Goldcoast Drive Cincinnati, Ohio 45249-1621 (800) 903-9247 Fax: (513) 671-3363 email: techelp@exair.com https://exair.co/58_423 See the Super Air Knife in action. https://exair.co/58_akv_ad

The Super Air Knife is the low cost way to blowoff, dry, clean and cool.

Blowoff Comparison Type of blowoff

PSIG BAR

Comp. Air SCFM SLPM

Horsepower Required

Sound Annual Purchase Approx. Annual First Year Level Electrical Price Maintenance Cost Cost dBA Cost*

Drilled Pipes

60

4.1

174 4,924

35

91

$50

$4,508

$920

$5,478

Flat Air Nozzles

60

4.1

257 7,273

51

102

$208

$6,569

$1,450

$8,227

Blower Air Knife

3

0.2

N/A

N/A

10

90

$5,500

$1,288

$1,500

$8,288

Super Air Knife

60

4.1

55

1,557

11

69

$632

$1,417

$300

$2,349

*Based on national average electricity cost of 8.3 cents per kWh. Annual cost reflects 40 hours per week, 52 weeks per year.

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Teschler on Topic Newsflash: Engineering starts to pay as well as finance The beginning of a new year is often seen as a time for fresh starts. So it may be appropriate that this new year could mark the first time in decades that engineering is considered a lucrative profession. The lament in recent years has been that the field of finance was attracting a lot of STEM graduates because it paid high salaries to those in analytical jobs, salaries that engineering companies usually couldn’t match. But a recent change in company reporting requirements shows this idea may be changing. We have the Dodd-Frank Act of 2010 to thank for this development. Among other things, it dictated that in 2018, public companies had to begin releasing what constitutes the total pay for their median employee as part of their filings with the Security and Exchange Commission. They compute this number by totaling up the pay and perhaps benefits (there is some leeway on reporting this) of all their employees excluding the CEO, then taking the average. The resulting number gives a revealing snapshot of pay scales. Before the rule kicked in, information about salaries could only be estimated from U.S. Bureau

of Labor Statistics data which are broad and next to useless. Though it doesn’t break down compensation by job function, the new Dodd-Frank rule is particularly helpful for sizing up companies employing lots of engineers and other STEM grads. For example, it turns out that some of the highest reported median wages are paid by pharmaceutical companies. Companies that employ a lot of software engineers are right up there with them: The median wage at Facebook Inc. is $240,430. At Alphabet Inc., (parent company of Google) it is $197,274, and the median employee at Netflix Inc. earns $183,304. The data also show it pays to be in the security software business. The median employee at software security firms Palo Alto Networks Inc. and FireEye Inc. earns $223,885 and $149,283 respectively. In addition, defense and aerospace workers seem to be well compensated. The median at The Boeing Co. is $111,204; at Lockheed-Martin Corp., $123,231; and at Raytheon Co., the median worker makes $144,589. It’s not uncommon to find firms paying a median compensation above $100,000. When I looked at a database maintained by the media firm Bloomberg LP, I found 204 firms that paid a median wage above

$100,000 in 2017. Only 25% of them were in the financial sector. I counted 33 of them in the tech industry. The lesson seems to be clear, at least for software engineers: Competent coders can demand top dollar. Interestingly, I only found five industrial companies paying a median above $100,000. It seems that the median pay drops a bit for companies that operate production lines. That’s the conclusion you come to from the figures for Eaton Corp., $71,073; Caterpillar, $65,770; Rockwell Automation Inc., $56,192; and Illinois Tool Works Inc., $40,738. The same can be said for hightech industries such as integrated circuit fabrication. For example, chip makers Texas Instruments, Microchip Technology Inc., and ON Semiconductor Corp. have median compensation of $78,951, $40,737, and $11,035 respectively. My guess is that median compensation figures are likely to push more STEM-oriented youngsters toward non-financial careers. One other probable outcome: Numerous employees will hand their boss a copy of the company annual report with the median compensation figure circled and then will announce, “I want the pay of a median employee.” DW

Leland Teschler • Executive Editor lteschler@wtwhmedia.com On Twitter @ DW—LeeTeschler

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Technology Forward What will change for 3D printing

in 2019?

In 2018, users of additive manufacturing technology saw a number of new ways to build parts layer-by-layer as vendors continued to explore how fast the technology could go. In addition, large manufacturers in aerospace and automotive continue to include additive technology in their product development and production efforts. So, what might be in store for additive in 2019? Recently Materialise offered its take on trends for 3D printing for this year. Here’s what the experts at the company had to say.

1. Applications, not technology, will drive the 3D printing industry forward The AM industry has been shifting its focus to identify the right applications for 3D printing for some time now. In 2019 that shift will intensify, as the application-driven approach to 3D printing is likely to gain attention from the financial world. Fried Vancraen, Materialise CEO, explains that the wheels are already in motion: “Investments are not going to machine manufacturers anymore but to companies and start-ups that apply 3D printing to create real added value in specific domains.” The objective is to widen the pool of industries using 3D printing, which creates a demand for products rather than supply for a non-existing market. But there are challenges. When a company adds additive manufacturing to its mix, design engineers need to adopt a new set of rules: it’s a move from ‘design for manufacturing’ to ‘design for additive manufacturing.’ Knowing what works for a design intended for metal casting isn’t enough when you’re making the switch to metal 3D printing. This is the main reason why many 3D printing players offer consultancy in design to additive manufacturing, to support new adopters of 3D printing with making the most of the technology for their applications. 2. A rise in polymer materials for 3D printing Last year was the year of metal 3D printing. This time, it’s plastic materials preparing for substantial growth in 2019, with material manufacturers playing a big role. Giovanni Vleminckx, a materials expert in Materialise’s research and development team, observed that material manufacturers like BASF are

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Tech Forward 1-19_Vs3.LL.indd 8

producing materials specifically for 3D printing. “New materials for 3D printing were not being produced because they were not processable on commercially available machines. Now, large material suppliers are signaling their willingness and drive to push forward with 3D printing technology. That’s leading to a steady fast growth for 3D printing plastics.” The rise of manufacturing applications, as opposed to prototyping ones, is fueling a growth in materials development. As industries identify ideal applications for 3D printing, material manufacturers will be driven to develop and certify new materials to suit those applications. This growth is especially important for industries like aerospace and automotive that need materials with specific properties and quality requirements. Industries will be able to choose the materials that best serve their applications, whether it’s for functional prototypes or series manufacturing. 3. What will also be needed is material standardization and better machine control. In the meantime, businesses continue to use tried and tested materials for newly identified applications. The emergence of 3D-printed eyewear as a vertical, for example, was founded on an existing material, PA 12; but the real boost will come with the introduction of new materials that fit the industry’s needs.

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Technology Forward

4. Software will be key to boosting productivity in 3D printing There is a consensus among Materialise experts that 3D printing is reaching a new level of maturity. “We need to get productivity and profitability up, and costs down. Software plays a key role in that,” says Stefaan Motte, Software Vice President at Materialise. Software makes it possible to automate tasks throughout the 3D printing process. “Automating manual labor during the preparation phase, also during and after production, is already a big help in making 3D printing scalable and cutting the costs down,” continues Motte. Another way to improve productivity is through simulating the 3D printing process. Simulation makes it possible for production operators to spot potential build errors before the build starts. Preventing failed builds can help reduce production costs drastically, bring down scrap rates, and increase overall profitability. 5. Technology-neutral interconnectivity, not proprietary solutions For 3D printing to claim a bigger share of the $12 trillion manufacturing market, the 3D printing industry needs to offer interoperability and technology-neutral solutions. If industrial manufacturers want to be serious about adopting 3D printing as a complementary manufacturing technology for final products, they simply cannot afford to be locked into proprietary solutions that limit their flexibility and choice.

6. Governments will get more involved We have seen 3D printing emerge as a discussion point in governmental environments, says Bram Smits, Public Policy Officer at Materialise, and this can be expected to increase in 2019. This rise is a signal that 3D printing is gaining importance in society and is freeing itself from the label of a prototyping technology. The main concerns for policy are the regulation of intellectual property and product liability. Underneath this is the concern that 3D printing could do to the physical object what the internet has done for music and movies: change business models and shift all the value to the digital file. “3D printing will disrupt supply chains but governments overestimate how much of the value is on the digital file. A part of the value will shift from the object to the CAD file and we need to think how we regulate these files,” says Smits. “The industry should get involved and talk to governments and explain what the technology can do, and what it can’t do and will never be able to do. With this we can create a safe and good regulatory framework that protects their citizens, designers and patients,” concludes Smits. “For 2019, we expect new users will continue to find their way towards additive manufacturing, and we’ll see an increasing number of companies shifting their production to AM or adding AM into the mix. … We don’t expect 2019 to become an inflection point in the history of AM, but the stage is set for another year of incremental steps towards an additive future.” – Fried Vancraen, Materialise CEO. DW

Leslie Langnau • Managing Editor llangnau@wtwhmedia.com On Twitter @ DW_3Dprinting

DESIGN WORLD

Tech Forward 1-19_Vs3.LL.indd 11

www.designworldonline.com 

January 2019

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1/13/19 12:50 PM


Green Engineering Paul J. Heney

• VP, Editorial Director

Building efficiency into garment

manufacturing

One of the industries ripe for more sustainability is the clothing/textile business. Fashion for Good is a platform for sustainable innovation that calls for industry-wide collaboration. Their aim is to make all fashion good, through their Accelorator and Scaling programs. According to the organization, on average, consumers purchase 60% more clothing than they did 15 years ago, but those items are only kept for half as long. Fashion for Good’s definition of the future of manufacturing is: The garment factory of the future will be safe, smart and clean. Garment workers will be upskilled from the sewing lines into new positions, where they are paid enough to thrive, not just survive. Innovations in automation, made-to-measure and 3D printing will make zero-waste manufacturing the norm. Here are four examples of current innovators:   Softwear Automation — This company has created Sewbots, autonomous robots that use patented robotics and revolutionary machine vision to move fabric to and through the needle quickly and efficiently, without the need for human hands. How quickly? Sewbots can sew a new shirt every 22 seconds, allowing for on-demand manufacturing that cuts back on inventory and waste.   Reverse Resources — An estimated 15-20% of material is wasted when clothes are manufactured. Typically, this material is burnt, sent to a landfill, or recycled into low-quality output like insulation. Textile recycling technologies exist and are getting even better through innovation — but one problem is that fabric mills, garment factories, traders, textile recyclers and brands don’t have an efficient way to talk to each other in order to put textile waste back into the production process. Reverse Resources in Estonia is out to help solve this pain point. They are creating a system to map, measure and track leftover textiles from garment manufacturing. Their system features a transparent, data-driven marketplace

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January 2019 www.designworldonline.com

DW Green Engineering 1-19_Vs4.LL.indd 12

that connects different actors in the supply chain. This increases visibility and makes it easier for recyclers to access textile waste so that it can ultimately be turned into new products and yarns. Scalable Garment Technologies Inc. — This Canadian company envisions a world where all clothing is created on demand. Through its knitwear manufacturing platform, brands and retailers would first design a garment. Then, customers would personalize the size, fit and material. Finally, SGTi would manufacture the custom garment on its 3D knitting machines. SGTi’s ultimate goal is to create high-quality clothing that fits and is produced quickly, affordably and sustainably. Not only will this result in dramatically less waste from unsold clothes, but it will also cut time and cost for the manufacturer.   Tamicare — This U.K. company has developed Cosyflex, the world’s first fully automated 3D-printing technology for apparel and footwear. The Cosyflex machine “sprays” colored fibers and polymers layer-by-layer, so an item can go from raw material to finished garment in as little as three seconds, depending on what it is. With Cosyflex, manufacturers can eliminate many of the typical steps involved in creating clothes, like spinning, weaving, knitting and cutand-sew. This opens them up to become more efficient, produce on-demand and open production hubs that are closer to shoppers. There are also many environmental benefits. Compared to the traditional way of doing things, Cosyflex eliminates cutting waste, reduces the amount of chemicals and water needed to dye fabrics and can use mechanicallyrecycled fibers. DW Fashion for Good | fashionforgood.com DESIGN WORLD

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Contents 1 • 2019

vol 14 no 1

designworldonline.com

2019

Leadership

106

| istockphoto.com

Pages 255-476

86 _MOTION CONTROL

128 _MECHANICAL

155 _ADDITIVE MANUFACTURING

Get your motor running....efficiently

Why spring choice matters

What application parameters and

Software that easily takes you from design to 3D print

industry requirements influence spring choice?

Today’s software helps streamlines the process of designing for 3D printing.

Choosing a stage actuation for dynamic-metrology applications

134 _PNEUMATICS

162 _LEADERSHIP

Proper air preparation for automated machines

Technology for all

measurement error and correct for the rest.

Available in many combinations,

106 _INTERNET OF THINGS

filters and regulators are a must-have on any machine.

Better communication standards for motion and robot systems

144 _ELECTRONICS

Innovative electric motors

Tips for more energy efficient induction and permanent magnet ac electric motor.

98 _LINEAR MOTION

The right motion system can minimize

For robots and cobots, good communication among system elements is critical.

114 _INTERNET OF THINGS A scalable communications infrastructure for IIoT sensor networks There are many factors to consider when

Former Google VP and White House CTO Megan Smith believes that greater diversity will make engineering teams stronger — and that data can solve some of our toughest problems. 175 _LEAP AWARDS

Novel axial flux designs could become LEAP Awards’ first year the primary means of powering future proving to be a huge success generations of electric vehicles. Here are the winners of Design World’s inaugural Leadership in Engineering Achievement Program (LEAP) competition.

choosing the right “last-mile” connectivity.

122 _MECHANICAL Simulation software improves bearing design

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CONTENTS 1-19_Vs3.LL.indd 14

A | S | B | P| E

A | S | B | P| E

American Society of Business Publication Editors

American Society of Business Publication Editors

American Society of Business Publication Editors

2018 Regional

2018 National

Fostering B2B editorial excellence

| istockphoto.com

Here’s how simulation software can help improve bearing design.

A | S | B | P| E

Fostering B2B editorial excellence

Fostering B2B editorial excellence

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DESIGN

Revenue of over $3 million

Revenue of over $3 million

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VP, Editorial Director Paul J. Heney pheney@wtwhmedia.com @dw_editor Managing Editor Leslie Langnau llangnau@wtwhmedia.com @dw_3dprinting Executive Editor Leland Teschler lteschler@wtwhmedia.com @dw_leeteschler Senior Editor Miles Budimir mbudimir@wtwhmedia.com @dw_motion Senior Editor Lisa Eitel leitel@wtwhmedia.com @dw_lisaeitel Senior Editor Mary Gannon mgannon@wtwhmedia.com @dw_marygannon

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COMBINE CHECK VALVE + END FITTINGS

MIX & MATCH BARB & LUER OPTIONS

CUSTOMIZE COMPONENTS

WHAT ARE MINIATURE MODULAR

CHECK VALVES? view details / watch 30 second video at: SMARTPRODUCTS.COM/CHECK_VALVES_SERIES_500_MINIATURE.PHP 1.800.338.0404

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Aerospace/military

Design for Industry Aerospace/military

How to keep

spacecraft fueled

O

One of the parts on NASA’s SpaceX’s CRS 16 spacecraft

was the CT-S cryocooler, a unit that helps ensure fuel does not boil off in space. The spacecraft is part of the Robotic Refueling Mission 3 (RRM3) that will pioneer techniques for storing and replenishing spacecraft fuel. The RRM3 platform will allow NASA to adapt technology that could dramatically change the way the space agency plans and designs for deep-space exploration. Currently, all spacecraft use consumables to perform key functions, such as maneuvering and maintaining critical equipment. These consumables eventually run out, rendering the spacecraft useless. NASA hopes to replenish these spacecrafts with consumables via robot to maintain their function and allow them to stay in space longer, eliminating the need to replace with another spacecraft. The RRM3 mission is critical to better understanding and perfecting this technology. The RRM3 mission builds on two previous robotic refueling missions: the RRM1 and RRM2. Roughly the size of a washing machine, the 550-lb RRM3 module will hang from a platform on the International Space Station. The RRM3 has a suite of three unique tools: Cryogen Service Tool, Multi-Function Tool 2, and Visual Inspection Posable Invertebrate Robot 2. The primary objectives of the RRM3 mission are to transfer liquid methane in microgravity and maintain the cryogen mass with zero boil-off for a period of six months. This mission marks the 82nd successful launch of a Sunpower cryocooler into space with zero cryocooler failures. The first Sunpower cryocooler was launched aboard the RHESSI satellite in 2002 and is still operating to this day with over 150,000 hours of run-time. Sunpower, Inc. is a business unit of the Materials Analysis Division of AMETEK, Inc. DW

www.sunpowerinc.com

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IMAGINATION

BATTERYHOLDERS.COM

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New!

Design for Industry Aerospace/military

Online gas spring sizing tool

Color sensors will capture images from Mars

Find & price the exact gas spring for your application in seconds! Try it today at: acecontrols.com/ calculations

N

NASA’s InSight Lander that recently landed on Mars is using color CCD image sensors for both the Instrument Deployment Camera (IDC) and the Instrument Context Camera. The camera on the Lander’s arm provides 3D color views of the landing site, instrument placement, and activities to inform engineers and scientists of the best spots for the seismometer and heat flow probe to gather measurements from the interior of Mars. While the InSight lander began its surface operations immediately, science data collection will begin roughly 10 weeks after landing. The image sensors will play a major role in helping scientists and engineers decide where to place the very specialized instruments to inform the best results of the study of Mars’ interior. DW

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Design for Industry medical

Stamping delivers complex dental appliance

G

Garmers Dental Instruments, Inc. has been in business for more than a century. Starting out as

a small dental practice in Minneapolis, Minnesota, it later grew into a successful dental instrument manufacturer. Herman Garmers was a practicing dentist who came up with an idea to improve the clamping structure for dental cotton roll holders. His vision was to create a holder that would securely hold the cotton rolls in the desired absorbent position. This instrument was patented on January 20, 1953. Cotton holders are used in various applications such as bleaching, cavities, fillings, and operative and restorative treatments. The holders provide more retraction, accessibility and visibility of the working area during a procedure. These are most important for use when a dentist is working alone without an extra pair of hands to help isolate the area being worked on. During the journey of developing his improved cotton roll holder, Garmers discovered he needed complex stamping pieces manufactured to secure the connecting parts of the instrument. This is where an accidental meeting provided Garmers with the partner he needed to produce the holder.

January 2019 www.designworldonline.com 24

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MDX Integrated Servo Motors Applied Motion Products is expanding our line of integrated motors with the addition of our first-ever integrated motors built on traditional 8-pole brushless servo motors. Using our innovative approach to integrated motors, developed over time with our integrated stepper and StepSERVO Integrated Motor products, we now introduce MDX Integrated Servo Motors for higher speed applications. Make it Move.

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A minor fender bender between Garmers and J.P. Boker, who happened to operate a stamping and washer manufacturing company in Minneapolis, turned into an immediate business relationship. At the time, Garmers could not find a supplier who was able to manufacture the stamped parts needed to complete his dental instrument in large quantities. Boker’s was known for its ability to make custom, complex stampings to match any customer’s specification. The Garmers’ cotton roll holder is a “household name” in the dental industry. The cotton roll holder securely holds any size or length of cotton in place during dental procedures. This keeps the cotton from rolling away or popping out. Another unique feature is the sliding chin clamp that keeps the holder in place on every patient, child or adult. “This chance meeting ended up being a perfect match for both of us and we have continued a strong business relationship that is now going on 85 years,” said Chuck Kersey, Assistant Sales Manager at Boker’s. “Both Garmers and Boker’s share the same principals of hard work, attention to detail, and moral and ethical behavior in everything that they do.” Boker’s, Inc., continues to specialize in producing high-quality custom metal stampings for dental and medical applications. This precision manufacturing covers a complete range of sizes up to 12 in. x 12 in. (flat) with thicknesses from 0.005 in. to 0.190 in. (varies by material) and draws of up to 3 in. deep and 8 in. in diameter. DW

Boker’s | bokers.com

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Design for Industry Medical

Angle sensors with easy mounting

W

With the ability to operate in temperatures ranging from-40 to +125°C, and a high immunity to emissions, these sensors suit a range of medical applications. Emission immunity meets or exceeds five EN 55022 and EN 61000 standards. The Vert-X 2900 Series of sensors measure angular position are available in single or redundant versions. Elongated holes make mounting easier. Users can specify configurations including start- and end-angles for less than 360° maximum range, index point, cw or ccw indication and non-linear curves. Measurement range is up to 0 to 360° with repeatability of 0.1° Mechanical range is 360° continuous. Available analog outputs are 10 to 90% of supply voltage and 5 to 95% of supply voltage. Other key Vert-X 2900 Series specifications include sample rate up to 5 kHz. The sensors are sealed to IP 67, life is ≥ 50 million movements and MTTF is over 650 years. DW

Novotechnik U.S. | www.novotechnik.com/vx29

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Design f o r I n d u s t r y Medical

Motorized miniature

translation stage

W

When a medical instrument design involves loads, precision, and low cost, consider the L-408 linear stage. Applications include research and industry including optics, bio-tech, and assembly of miniature components and photonics instrumentation. The compact X-axis linear stage delivers precise motion and reliability with anti-creep crossed roller bearings. Driven by a highresolution leadscrew with 0.5 mm pitch, minimum incremental motion of 0.1 microns (100 nm) is achieved over a travel range of 1 in. (25 mm). Despite its compact dimensions, the stage can handle payloads of 44 lb (200 N) and provides a push/pull force of 11 lb (50 N). Stepper and servomotors are offered with direct-drive and gearbox options. The maximum velocity of the direct-drive stages is 10 mm/sec. The unidirectional repeatability of all versions is 0.5 microns. High resolution, motor-mounted optical encoders provide position feedback to the motion controller for closed-loop operation. Noncontact, optical limit switches and reference point switches with direction sensing in the middle of the travel range simplify use in automation tasks. Features include: 0.1 - 0.5 µm min. incremental motion 8 – 122 nm encoder resolution 1 -10 mm/sec max velocity 40 – 50 N push/pull force DW

PI | www.pi-usa.us

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Design f o r I n d u s t r y Food/beverage

Sanitary conveyor delivers better access for cleaning

P

Perhaps the most important

feature of a

sanitary belt

conveyor is the

ability for it to be

thoroughly cleaned. The AquaGard 7350 V2 Series with tip-up tails checks off that box. The AquaGard 7350 V2 with tip-up tails gives ample access to the inside of the conveyor for effective, fast cleanings, and easy maintenance. Tails can be tipped up in just a few seconds with no tools, and then retracted and locked back into place with the same minimal effort. Tip-up tails are standard on the AquaGard 7350 V2 straight-belt models, and also available on straightrunning modular belt units. They come with improved strength in the tail for more rigidity and no flexing, as well as supporting the belt/chain closer to the tail for improved performance. The conveyor is built for sanitary applications within baking, snack food, pharmaceutical, pet food, packaging and other industries that require wipe-down and occasional washdown cleanings. The conveyor comes in straight belt, as well as modular belt straight and curve models. Belted LPZ, modular belt LPZ and positive drive models will be available in the coming months. The modular belt curve conveyor has no openings greater than the international standard of 4 mm, even within the curves, which increases safety by eliminating pinch points for operators. Added safety measures include covering the upper and lower chain edges, and fully containing the drive system, which reduces catenary belt sag and conveyor noise.   Space reduction is another improvement on the AquaGard 7350 V2. The modular belt conveyor system is designed to maximize available plant space by keeping the footprint as compact as possible. Infeed and outfeed sections are a compact 18”, further saving valuable floor space. DW

Dorner | www.dornerconveyors.com

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Inertia Dynamics Matrix Stromag Warner Electric Warner Linear

Altra Electric Clutches & Brakes brands offer the largest selection of clutches, brakes and linear actuators available from a single source...worldwide.

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Design for Industry Food/Beverage

T18-2 sensors from Banner Engineering withstand washdown and thermal shock environments.

Sensor selection tips for washdown and

other harsh settings

S

Sensors are machine edge devices, so are on the front lines — often completely exposed to the worst of what automated assemblies endure. In a recent Design World interview, Banner Engineering global business development manager for sensors Dana Holmes answered several questions about sensor survival in these harsh environments. Here’s what she had to say.

DESIGN WORLD

DFI 1-19.v6.LL.indd 37

Design World: Explain about sensors for harsh environments. Banner Engineering: Harsh environments can imply a washdown environment in the food and beverage industry, or it can just mean a setting subject to vibration or temperature swings. But when engineers refer to extreme environments, they typically mean washdown-type settings — as that’s where most end users need

www.designworldonline.com  

January 2019

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Design for Industry Food/Beverage rugged sensors. We manufacture sensors aimed specifically at satisfying specific IP ratings needed for these environments. Some of our sensors also include features to support hygienic conditions — to prevent debris buildup and the growth of bacteria. We also put potting material inside certain sensors to help them withstand temperature cycling. Design World: What kind of features are these — smooth surfaces or special housing plastics? Banner Engineering: Component materials are key to surviving these environments, as end users will sometimes use chemicals to aid in the cleaning of equipment. Stainless steel withstands exposure to many such chemicals, but not all of them. Other metals can corrode in chemical environments — and some plastics even melt. Design World: Where can design engineers learn about which materials work where? Banner Engineering: We publish chemical-compatibility information on the data sheets. One common issue is that design engineers and OEMs know little about the environments where these sensors will ultimately be installed. In contrast, it’s

easy for end users to describe application settings — because they know exactly what their personnel are using. That means in most cases they can even provide us with a list of chemicals and say, “Here is what my facility uses” and sometimes more importantly, “Here are the concentrations we use.” A 20% concentration of a chemical might be fine for a certain plastic, but 30% will make it erode. A related issue is that customers will often tell OEMs, “Our machine isn’t going in a washdown area, so don’t worry about that” or say, “This design will never come in contact with chemicals.” But the next thing you know, we’re getting a melted product back because it did indeed come in contact with chemicals. Design World: Would you describe a nasty setting — or a product that came back damaged from an extremely challenging environment? Banner Engineering: I just visited a case-packer OEM. Their customer was using their equipment to pack bottles into cartons. The end user told the OEM, ‘There won’t be any material spilled, as it’s a completely dry environment — it’s fine.’ So the OEM installed standard metal Q3X laser contrast sensors as well as some plastic sensors on the application. Well, what the

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Design for Industry Food/Beverage Design World: Anything else that we should mention about extreme environments?

This is a Banner Engineering Q3X laser contrast sensor for high-speed detection and fixed background suppression. Its nickel-plated zinc housing withstands even environments with cutting fluids and oils. end user didn’t mention was that the capper wasn’t working very well, and the material they were putting in cartons was actually bottles of hydrochloric acid — a 30% solution of hydrochloric acid. When bottles came down the conveyor, they were spilling hydrochloric acid all down into the machinery. Next thing we know, the lenses on some of the sensors melted, because they’re made with plastic and not meant for that type of environment. So we had to go back and swap the sensors to fiber-optic variations that are Teflon-encapsulated. Such sensors can survive that 30% solution, as can select plastic sensors and lenses. We and the OEM just needed to know more about the actual application. Design World: When you say ‘encapsulated’ do you mean the sensor body is filled with a silicone resin?

Design World: Talk a little about what actual sensing functions work in harsh settings. Banner Engineering: Photoelectric sensors are a strength of ours, and they excel in many situations … but rely on light to function. So wet settings or places where material will collect on lenses are challenging. Such manufacturing environments can be served better by ultrasonic technology. That said, photoelectric sensors employ visible red LEDs or infrared LEDs … and the latter actually does better in steamy environments. That’s especially true in opposed mode sensors with a lot of power, they aren’t affected by large water particles in the air of a steamy environment. These sensors essentially burn through that volume better than traditional options.

Banner Engineering: We cover the sensor with Teflon — to act as a protective sleeve that goes over the tip of the fiber-optic assembly.

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Banner Engineering: We ask end users to really understand what’s happening in the environment and share as much as possible about that — so we can help get them into the right product. On the hydrochloric- acid application, we could have designed around that substance upfront — and avoided failures. Settings with temperature cycling — as in dairy or meat processing plants — are also unique. Rooms must stay cold to keep product safe and fresh. But after product goes through, all equipment gets a washdown with hot water. That means machinery goes from very cold to very hot — which can cause condensation as well as thermal expansion and contraction. Some sensors handle this better than others. For example, thermal cycling on metal and plastic joints is pronounced because the materials expand and contract at different rates. That means there can even be openings in those joints — allowing water ingress. So design engineers must be cognizant of this. We manufacture very rugged sensors to survive extreme temperature swings — in some cases, ultrasonically welding polymer sensor halves together so they have a monolithic body that will always stay impenetrable during thermal cycling. Thermal cycling is also a challenge in how it causes condensation inside sensors. For these applications, we’ll fill the sensor with epoxy — so there’s no air on the inside to condense and interfere with the sensor optics. High-pressure spray during washdown is another challenge. Some end users call IP67 washdown, while for others washdown is IP69K. It’s key to understand washdown definitions — and the difference between machinery that gets wiped off and machinery that gets hosed down with no pressure. These situations necessitate IP67 products. But if a machine takes rigorous cleaning with high-pressure high-temperature spray, that machine will need IP69K product. DW

Banner Engineering www.bannerengineering.com

DESIGN WORLD

1/15/19 9:19 AM


Change the way you look at pressure measurement

oem pressure transmitters

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Design for Industry Food/Beverage

Protect automation against outages

T

The interruption or loss of power in a

food and beverage plant is estimated to cost between $100,000 and $1 million per hour, highlighting just how dependent industry is on the continuous supply of electrical power. For food and beverage manufacturers, the absence of electrical power for even a brief amount of time can result in a loss of productivity, product and revenue. For example, in the dairy industry, accurate tracking and tracing of the product throughout the process is invaluable. Dairy product is typically monitored by a process control system but, if the plant loses power, then the program being executed through the system is also interrupted.

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If the system is unable to record or process the collected data, this can pose a risk of non-compliance with food safety regulations. If the plant is unable to trace critical tracking events such as the transfer of raw milk into a pasteurization vessel or milk powder being transferred from a spray dryer to a silo, the product may have to be discarded. It’s not just about securing process data either. In another example, a study from Climate Central found that 80% of outages between 2003 and 2012 occurred because of harsh weather conditions. However, with the power quality technology available today, manufacturers can protect their equipment from losing data as a result of unexpected outages, while also reducing operational costs. Uninterrupted power supply (UPS) systems can maintain power to equipment, especially the automation network and control systems (like PLCs) in

the event of a primary power supply failure. This not only reduces the risk of food getting stuck on production lines, but also maximizes the availability of performance data. The PCS100 UPS-I has been designed with a failsafe electro-mechanical bypass that ensures protection against power quality events. It protects sensitive loads from sags, surges and outages by using ultra capacitor or battery energy storage and provides continuous power supply in food and beverage plants. Even applications that experience frequent disruptions because of voltage variations, like high-speed packaging lines are safeguarded with UPS. UPS systems are generally designed to shield a facility’s system from short-term dips and spikes in the power supply. In the event of an extended outage, a UPS system can allow the computer center staff to shut down critical equipment safely, while ensuring that data integrity is maintained.

Although UPS systems are not generally designed to maintain power during extended power outages, they provide an important function in unexpected situations and should be used as a means of protecting mission-critical equipment for food manufacturers. As noted, a critical application is for manufacturers processing products that require accurate levels of traceability. DW

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Design Notes

Chain-stretch monitoring system helps power transmission plant Edited by Mike Santora • Associate Editor

Chain drives are a critical part of the manufacturing process in many industries, whether the chains act as conveyors for glass containers or transport automotive frames down kilometer-long production lines. Regardless of the industry, the vibration and constant pull on chain links can stretch, distort, and even break weakened links if they are not properly maintained, causing unplanned downtime as well as lost productivity and profits. The automotive manufacturing industry’s traditional dependence on chain drives has prompted production engineers to look for better ways to monitor chain drives. Until recently, Cognex automotive manufacturers inspected each link using In-Sight 2000 camera scanning a chain link.

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a rectangle of metal of the same length as a new chain link. A technician visually checked each link as it passed. If a link looked problematic, the technician marked the chain and hoped it would continue to function until the next scheduled maintenance. If the chain broke in the meantime, the manufacturer incurred expensive downtime until the chain could be repaired. Working with Cognex, engineers at automotive manufacturer General Motors of Canada Company (GM Canada) developed a chain drive stretching system that measures every link in real time and automatically marks non-compliant links without slowing or stopping the line. After discarding a solution that used discrete photoelectric sensors combined with laser pointers to measure chain link lengths, GM Canada engineers developed a real-time chain link monitoring system based on a Cognex In-Sight 2000 vision sensor. The In-Sight 2000 solution uses a red LED illuminator to backlight the chain to provide a crisp outline of the link under inspection, while a complementary red filter helps eliminate the effects of ambient light. A proximity sensor provides the trigger signal to the camera as each link passes within its field of view. Cognex’s In-Sight Explorer image processing software takes the images and runs edge detection algorithms to identify the center of each chain link and then uses a caliper tool to measure the internal length of the chain. “Basic pass/fail inspections can be accomplished with intuitive, point-and-click setup tools,” says system designer Christopher Eid of GM Canada’s Electrical Engineering– Paint Department. “In this case, edge detection is used to locate the presence of the edges of a link. If both edges are found, the distance between the two connections is

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In-Sight software in“easy builder view” for chain-stretch monitoring. The center image shows a chain link and its internal length. The top right column shows the In-Sight Explorer algorithms used in the inspection process, while the lower section shows the pass/fail result for each chain link.

measured, and the result is placed under the respective chain-stretch limit category. The result is then sent to the PLC, which then communicates with the HMI and displays the relevant information.” Using the caliper measurement, GM Canada’s system determines each link’s percentage of variation from the norm. When the variation reaches 4% or more, the vision system sends a signal to a nearby PLC through an optional I/O module. It counts how many chain links fall within each category, as well as the number of rotations for a 1,680-foot chain. The PLC allows the user to measure links at the first detection of a conveyor magnet (reference point) by pressing “Start Now” or by discretional scanning. The user can also decide how many revolutions of the conveyor chain the Cognex system will measure during an evaluation session. “So far, we’ve tested the system on our fastest conveyor,” explains Eid. “We started at 70% coverage because the camera runs faster than the PLC. Today we’re doing most of the analysis on the camera, and we use a 9-frame buffer bit on the Cognex vision sensor, which allows us the ability to cover more coverage per scan. Based on

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Design Notes

HMI for control and for displaying chain-stretch results.

the success of the system, we plan to roll several more systems shortly and eventually modify the system for overhead chains for painting stations too.” According to Eid, eventually, the PLC will direct a downstream paint sprayer to mark chain links that fall in the 4–5% stretch category for replacement during the next planned maintenance cycle. As vision sensors gain the speed and power necessary to keep up with the fastest industrial applications, engineers realize that cobbling together discretely wired “dumb” sensors and software is a waste of time and money, especially when vision sensor acquisition and deployment costs are weighed against the regular costs of unplanned downtime. DW

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Design Notes

Rotary seals alleviate fluid power pressure build-up

Edited by Mike Santora • Associate Editor

Leaking rotary seals can create a headache for anyone within the fluid power industry. There is a fine line between ensuring a rotary seal has enough lubrication to prolong a seal’s life and having so much it causes leakage. Without sufficient lubrication, the seal life is shortened due to excessive wear and heat. System costs also increase due to additional frictional torque. To remedy potential issues with leakage, fluid power design engineers can take a few precautions, such as the use of redundant seals or a drain line. Manufacturers can lower hardware cost and increase functionality with new sealing innovations designed to decrease torque and increase seal life. For instance, using a seal with an integrated check valve function and high contact force on the seal edge helps to increase lubrication while decreasing leakage. In redundant sealing systems, the check valve function automatically releases inter-stage pressure build up when system pressure drops. Seal designs with valve ports made from both sides of the O-Ring profile to the space in the center provide a lubricating groove. Like other O-Ring-activated slipper seals, the initial squeeze of the O-Ring ensures enough contact pressure between seal and mating surface to provide sealing at low pressure. As the system pressure increases, the O-Ring and the seal body have direct contact force on the sealing surface to ensure sealing efficiency at all pressures. A double-acting four-lip seal installed in the lubricating groove prevents static leakage through the ports. When this lip seal is pressurized from one side, it opens the port on the pressure side, equalizing the pressure beneath the elastomer ring. This double-acting Seal diameters can range from about 1 in. to rotary seal delivers twice 2 ft-2 in. (22 mm to 660 mm) and operating temperatures the pressure velocity and a can be from -22 to +392 °F (-30 to +200 °C), making them 50% reduction in friction. well suited to fluid power applications. In testing, wear of the seal and O-Ring was so low that its measurement was inconsequential.

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A solution like this provides multiple seal points on the ring, requiring less compression to provide an effective seal. By creating less force to seal, there is less friction and wear, reducing potential downtime. When pressurized, the elastomer ring opens the port on the pressure side and equalizes the pressure beneath the double-acting four-lip ring — pressure balancing the seal by more than half. Shifting pressurization through the ports renews the fluid in the space between the “legs,” improving lubrication under the seal. This level of lubrication is optimal because the grooves on the inner and outer diameter of the ring maintain lubrication, lowering friction and extending the life of the seal. The sealing industry has answered a need for rotary seals that run at higher speeds at higher pressure and extended seal life for more demanding applications where a high pressure to velocity value is required. This double-acting rotary seal delivers twice the pressure velocity and a 50% reduction in friction. In testing, wear of the seal and O-Ring was so low that its measurement was inconsequential. Specialized rotary seals can be well suited to address highspeed, high-pressure applications that need continuous service at high and low-pressure velocity (PV) values. The seals give improved performance in oscillating conditions and applications involving frequent pressure and velocity changes. These doubleacting rotary seals are tested with low frictional torque at all pressures from 0.5 MPa / 72.5 psi and above with low sensitivity to pressure increases from 0.5 to 20 MPa / 72.5 to 2900 psi. They are suitable for equipment for which a long service life is required in demanding service conditions. Hydraulic swivels, lead-troughs, rotary connections with swivel movements, excavators, hydraulic rotators, robots, manipulators, indexing tables, pivoting motors, hydraulic motors, blow molding machines, top drives and core cutting equipment and other applications would benefit from rotary seals that can run at higher speeds combined with higher pressures. They not only achieve these requirements but generate lower heat, which reduces the wear on the seal. For the equipment operator, that means lower overall costs from reduced maintenance requirements and energy consumption. DW

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Design Notes

Testing lubrication methods to prolong life in

flexible shafts

Edited by Mike Santora • Associate Editor Flexible shafts have been used for many years in a variety of physically stressful applications. Over the years, customer service lifetime requirements have become more demanding, resulting in the expectation that end-of-service products should behave like new ones. To meet this expectation for flexible shafts, a product that provides lifetime lubrication without the need for maintenance activities is needed. The principle performance characteristics of a flexible shaft are straightforward —the challenge is to sustain these characteristics over the product’s lifetime. This is because throughout the life of a flexible shaft, internal wear and settlement of the internal structure takes place. Consequently, after a high number of revolutions in both directions, the angular, torsional deflection traditionally increases. As the wires that make up a flexible shaft rotate around themselves, the individual wires move across each other causing wear. The geometry of the round wires creates high loads generated at the contact points where they cross with the wires of the adjacent layers running in the opposite direction (see figure 1). These high loads and displacements from torque transmission and bend radii mean the wear can become dangerously high for long endurance service life applications or where precise angular control is important. The construction of flexible shafts precludes the selection of differing materials on alternate layers to reduce galling and pick up, as this can lead to a lack of directional balance in the shaft and give rise to galvanic issues. Traditional lubrication methods, as historically used in low speed torque load applications work well but at higher speeds and torque loads the contact pressures become too high. Using traditional lubrication methods, flexible shafts can degrade quickly at first, and over time require either maintenance or replacement, both of which are costly in many applications. Dry Film Lubricants (DFL) have been successfully applied to the exterior of shafts when used in conjunction with formed metallic tubes; the challenge was to manufacture a shaft that contains DFL throughout its construction. The use Figure 1 of DFL in combination with a traditional lubricant Illustration of a also seemed worthy flexible shaft’s of investigation and construction development.

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Samples were produced from the same shaft construction with various lubrication media in isolation and in combination with each other and tested under the same test conditions. The test regime was highly aggressive in terms of torque load, speed and bend radius to reduce the testing duration. A limit to the number of revolutions was set. Principle data recordings were temperature while running and torsional (angular) deflection, taken at defined rest intervals. From the testing, two distinct groups of results emerged. Group 1, circled in green in figures 2 and 3 above, contains flexible shafts treated with traditional lubrication methods and those with DFL throughout their construction. Group 2, circled in red, contains flexible shafts with either no DFL or only surface DFL. Within these groups, dry samples with no lubrication failed early and produced

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Design Notes Throughout the life of a flexible shaft, internal wear and settlement of the internal structure takes place. Consequently, after a high number of revolutions in both directions, the angular, torsional deflection traditionally increases.

the least favourable results. Of the better performing group, Group 1 (lower temperature and lower torsional deflection), only one of the samples was dry. Of the group lubricated through DFL methods, method 2 out-performed the other application methods. Traditional lubricants work well to suppress the internal friction within a flexible shaft (friction can be correlated to temperature) as does DFL. DW

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Design Notes

One Mega-Fixu storage unit has space for approximately 30,000 medication packages.

Robot-assisted order picking system

automates medical supply processes Edited by Mike Santora • Associate Editor

Finnish company Newlcon Oy’s Mega-Fixu storage and retrieval system completely automates the identification, shelving and dispensing of medications, enabling pharmacists and medical staff to streamline their storage management. Regarding scale and cost, each NewIcon Mega-Fixu storage system is custom-tailored to fit the size and turnover of the particular pharmacy. To accomplish these tasks, Newlcon Oy needed a solution that could integrate PLC, image processing, and database functions.

AM8000 series servomotors with One Cable Technology (OCT) ensure that the robot is in the right position for package handling.

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Newlcon Oy chose to have the control system and database run on a Beckhoff C6650 Industrial PC (IPC) equipped with an Intel Core i7 quad-core processor as well as a RAID controller and redundant hard disks. The control system, database, and ERP link are based on TwinCAT automation software. “The reliability and performance of the IPCs are critical to us because the database comprises 150,000 data points for the various storage positions,” explains Mika Rissanen, automation manager at NewIcon. “Also, the openness and modularity of the solution were among the criteria that solidified our decision to employ PC-based control technology. The modularity of our system perfectly matches the modular control architecture offered by Beckhoff. We also had the ambitious goal to integrate the database, image processing, and automation system on a single PC platform.” The Mega-Fixu system has a robot-assisted input unit where each package is identified and measured via a barcode reader and an intelligent image processing system. Following this step, the control system determines the most suitable storage location for the package. The system’s X/Y servo axes controlling the robots that shelve and retrieve medicine packages are equipped with AM8000 series motors that feature One Cable Technology (OCT), as well as 2-channel AX5000 Servo Drives. The servo axes’ movements are controlled via DIN rail-mounted CX5020 Embedded PCs. Future developments include predictive diagnostics and condition monitoring.

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Design Notes All the controls of the NewIcon’s Mega-Fixu system are based on Beckhoff automation components, ranging from the C6650 Industrial PC as a database server to CX5020 Embedded PCs that control the storage system, conveyor and drive components. All communication functions are handled by the EtherCAT real-time industrial Ethernet system.

“Since the order picking systems for pharmacies and hospitals must work trouble-free and be highly reliable, it’s best when service and maintenance are performed proactively,” Rissanen says. “The number of systems we have shipped has increased so rapidly that we are considering an even more comprehensive

diagnostic and monitoring approach.” TwinCAT IoT and TwinCAT Analytics software tools will help in this effort, according to Rissanen. “They will make it easy for us to integrate cloud-based services and automated diagnostics into our systems in the future,” he says. DW

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Design Notes

HDFB-Coupling assembled to gearbox shaft and metallic conveyor drive. (HENFEL)

How sweet it is: Coupling assists in sugarcane processing application By Matheus Mendes The sugarcane industry is one of the most flourishing segments of the Brazilian Economy. With a production of up to 624 million metric tonnes of sugarcane in the 2017 harvest season, the country holds the world record production for both sugar and ethanol from this raw material. Uniting technology in both agricultural and industrial fields as well as sugar and ethanol production, demands a great deal of synchronism between these areas, from harvest and delivery of the raw material to the plant up to the milling process. A non-scheduled maintenance stop can disrupt the entire production chain, decreasing productivity, and profitability of the company. In a sugar and ethanol plant located in the countryside of Sao Paulo state, the maintenance engineering department carried out a predictive maintenance operation in cooperation with HENFEL (a part of Ringfeder Power Transmission): The goal was to mitigate the breaking risk of three conventional elastic couplings. Due to their constructive design, the existing couplings presented the risk of causing a non-scheduled maintenance stop of up to 36 hours, which would generate an estimated financial loss of up to 845,000 EUR.

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The existing elastic couplings were installed at the drive of two feeding tables at 45º and one metallic conveyor: essential pieces of equipment for the reception, preparation, and handling of sugarcane in the first crusher – all raw material processed by the plant goes through this system. The aforementioned elastic couplings were assembled with an interference fit on the shafts of both the gearbox and the equipment. This procedure requires heating to obtain thermal expansion of the coupling hubs, allowing the parts to be mounted by axial sliding. This procedure often requires special tools such as inductive heaters or a burner flame. The use of an interference fit is a common method in South America for axially assembled couplings. However, this fixation method involves some “inconveniences” that should be considered. Over time, the exposure of the coupling to humidity (vapors, rain, and liquid of the productive process) and other contaminants generates oxidation between the parts: This makes removal operations very complicated, often requiring hydraulic tools – which proves very difficult to carry out such operations in-house. Accordingly, in most cases, it is necessary to remove the components including the mounted coupling hubs and send them to a workshop to have them separated.

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customer retrofitted the drive of two feeding tables at 45º and the metallic conveyor. The HENFEL team recommended the use of the split elastic coupling type HDFB: This coupling type provides torque transmission through the compression of elastic buffers which absorb shocks and vibrations generated by the system and also compensates angular, radial and axial misalignments. Manufactured of ductile cast iron in accordance with the EN-GJS-450-10 standard, the HENFEL HDFB couplings with split hub design are very durable. Additionally, the split design allows radial assembly and disassembly. These types of couplings provide many benefits to the application when it comes to maintenance operations and reliability. In the presented case a reduction of more than 20 hours of the assembling / disassembling operations was achieved. Furthermore, since there was no need to displace the drive components when using this coupling type, the original alignment between the shafts was preserved. Last but not least, since 2015, when the first coupling was installed, no failure has occurred during the harvest period with the plant operating 24/7. DW

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IronCAD, the 3D computer-aided design platform for metal fabrication and custom machinery manufacturers, has been updated to IronCAD Design Collaboration Suite 2019.

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IronCAD, the 3D computer-aided design platform for metal fabrication and custom machinery manufacturers, has been updated to IronCAD Design Collaboration Suite 2019. This is the 20th anniversary edition of the software. The software continues its performance with the large assembly designs and workflows needed by machinery manufacturers. IronCAD was originally based on the idea of “design for all,” said Tao-Yang Han, IronCAD’s president. The new release extends IronCAD’s Shrinkwrap capability to simplify imported and native models and gives users the ability to load the simplified or full versions based on their preference. Typically, a design team receives from their partners the files they will need to use in their own design. They can use the Shrinkwrap tool on imported data to remove unnecessary geometry, which reduces the size of the design file and improves graphical and process performance during operations and loading.

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This shortens the design cycle, Han said. Users also can load either the simplified or the full design components in their working file. Using the simplified version allows designers to focus on the design tasks and limit the performance impact of unrelated areas. Whether it is native design data or imported, users can use the Shrinkwrap capabilities to optimize their design process by reducing the time it takes to process larger data sets. Users can also use the Shrinkwrap tools to hide selective parts, nonvisible parts, and hole and pocket regions while allowing critical components to remain. This is essential for downstream sharing because companies need to protect their intellectual property while offering a reasonable-size model for sharing. IronCAD’s Web Viewer has been enhanced so users can easily share 3D Designs with anyone with an internet connection and a HTML 5 supported browser on any device. Simply load your design in IronCAD, and select the Share button. Users will receive a hyperlink to the file that they can share with their collaborators to load, view, and interrogate your 3D design. The files are automatically deleted a week later, so users don’t need to keep a repository or storage device for their collaboration process. IronCAD’s Smart eBehavior allows users to build intelligent connection, position and orientation. Customizable rules, another major focus of the updated edition, give users more methods for defining connection locations and naming them with alias names to make them easy to identify. Users also have access to mechanism behaviors when connecting components in cases like four-bar linkages. This edition includes a number of enhancements in the user interface. Improvements such as bold edges, updated handle and TriBall displays, quick sizing behaviors on input, direct input on drop of features, improved dimensional display in sketches, and direct access to the TriBall positioning tool improves the usability of the software. DW

IronCAD | www.ironcad.com

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CAE Solutions Theorem Solution’s Inventor to JT Visualize Translator gets an upgrade

T

Theorem Solutions recently released version 21.3 of its Inventor to JT Visualize 3D translator, which supports Autodesk Inventor 2017, 2018 and 2019, and up to and including the JT file format version 10.0. Theorem’s Visualize 3D products create visualization data for users of digital mock-up, virtual reality or desktop applications and support the translation of assembly structure, geometry and attributes. The Inventor to JT translator has been developed using the Autodesk Inventor Development Environment and translates up to and including the latest versions of Inventor data into the JT file format. The translator can be run using the freely available Inventor View application as a minimum system requirement, so access to a full license of Inventor is not required. The translator processes all JT assembly types, regardless of data structure. A new user interface helps the development and streamlining of translation and downstream processes by allowing engineering data to be filtered, viewed,

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interrogated, manipulated and translated interactively or in batches with the ability to publish user specific documentation. Since the JT open standard became ISO certified in 2012 and then ISO-revised in 2017, the 3D data format, most CAD programs have adopted JT functionality. ISO JT V2, the revised ISO standard, includes the incorporation of a STEP B-rep as an additional B-rep segment. JT is a standardized 3D data format used for product visualization, collaboration, CAD data exchange, and sometimes for long-term data retention. The JT file format can store an arbitrary number of faceted representations with varying levels of detail. It can contain any combination of data, including NURBS surfaces, product and manufacturing information (PMI),

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and metadata, either exported from native CAD systems or inserted into product data management systems. Theorem’s strategic partnerships with Autodesk and Siemens ensures that there is a parallel development between the latest releases of Inventor, JT and Theorem’s Visualize 3D products, allowing Theorem to continue to provide data solutions to the Inventor and JT communities. JT is useful to CAD visualization systems, which don’t need the full capacity of the original CAD system. Rather, suppliers and others can view the CAD drawing without the need for access to the CAD program that created it. JT is useful here because it can house lightweight geometry and product manufacturing information from CAD systems.

The JT standard was originally created by Engineering Animation and Hewlett Packard and at that time it was called Jupiter Tessellation. By dictionary definition, a tessellation is an arrangement of shapes closely fitted together, especially of polygons in a repeated pattern without gaps or overlapping. Following a series of company acquisitions, the 3D data format is now under the purview of Siemens PLM Software, headquartered in Plano, Texas. JT is the common interoperability format in use across all of Siemens PLM Software and has been adopted as the long-term data archival format across all of Siemens. The format was originally created to support the interactive display of very large assemblies containing tens of thousands of components. When

the whole product is displayed on the computer screen, the hosting the visualizing application displays only a simple model. However, as the user zooms into a particular area, progressively finer representations are loaded and displayed. Over time, unused representations are unloaded to save memory. DW

Theorem www.theorem.com

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CAE Solutions Autodesk updates Fusion 360, additive, and Generative Design capabilities

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Future products will be designed with their capability to be

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manufactured in mind, according to Autodesk executives, who spoke at Autodesk University, a gathering of users of their technology. The company has updated its software accordingly and made strides to further the use of cloud capabilities, generative design and additive manufacturing, said Greg Fallon, vice president of business strategy and marketing at Autodesk, a maker of engineering and construction software. “We see our customers embracing this evolution and, for our part, we’re pushing to accelerate it. Because when you break down the silos between product designers, mechanical engineers and manufacturing engineers, and treat all these people as a real team, you improve just about everything about the product development process – speed, cost, innovation,” Fallon said. Fallon and his colleague Steve Hooper announced updates to the company’s generative design capabilities as well as to its product design and manufacturing collection of software. This includes customers such as Whill, a maker

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of a portable mobility chair that has been re-imagined and made lighter using Autodesk generative design. ”We’ve known since people started making things that thinking about how things are made while you’re designing them makes it easier to make them,” added Hooper, vice president for Fusion 360. Updates include a collection of tools that work inside Autodesk’s Inventor (including Nastran In-CAD, HSM, and a nesting utility). Also new is a suite of specialized toolsets available with AutoCAD, and a cloud-based technology offered with Fusion 360, Fallon said. The Fusion 360 integrated workspace includes a hybrid manufacturing experience that combines advanced additive and CAM capabilities in a single workflow, Hooper said. “We’ve developed a comprehensive design-to-print workflow for additive manufacturing, based on Autodesk Netbabb and Fusion 360, that connects Autodesk generative design technology with HP Multi Jet Fusion 3D printers,” Hooper said. “By streamlining the conversion of digital design to physical part, the new workflow will increase accessibility to rapid prototyping while accelerating our customers’ ability to deliver production-ready 3D printed parts.” “Our goal has been to develop a single product that serves the needs of this entire process and the professionals who perform it, not a point-based solution. That’s why we built Fusion 360,” he added. Autodesk is working to expand the manufacturing for generative design to include 2- and 2.5-axis machining, meaning designers will be able to specify those machines when working on a generative design. “While additive manufacturing and 3and 5-axis milling constraints are already available for generative design, the addition of 2 and 2.5 is a big deal because pretty much anybody with a CNC milling

machine–even the most affordable ones –has those capabilities at their disposal,” Hooper said. In addition to having access to Fusion 360’s cloud-based generative design, advanced simulation and advanced CAM capabilities, new subscribers will receive 100 cloud credits as a one-time grant. Autodesk cloud credits are the currency for cloud-based services, including generative design, so you pay only for what you use. “Incorporating the unique voxel-level capabilities of HP Multi Jet Fusion with Autodesk generative design unleashes new levels of creativity, speed, and quality from prototyping all the way to production,” added Michelle Bockman, global head of 3D Printing commercial expansion and development at Hewlett Packard. “By empowering the vast Autodesk customer ecosystem to design for 3D across HP’s entire 3D printing portfolio, including our full color platform, we are unlocking new possibilities for customers and furthering our mission to change the way the world designs and manufactures.” DW

Autodesk | www.autodesk.com

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CAE Solutions Headset to help engineers with “VR Snacking”

A

At the Autodesk University Conference, HP unveiled its Opera Glass, a headset designed for “VR snacking.” The headset is for engineers who want to design in 3D CAD, then quickly view the model in virtual reality. It helps engineer switch quickly, and often between CAD and virtual reality. Wearers can switch while seated or standing at a desk. Opera Glass solves the issue of switching to a VR application and disrupting the workflow because the designer must move to a dedicated VR space. These concept glasses let designers look at the design in the VR view, HP says. The glasses are attached to a stick near the designer’s computer monitor, so users can bring it to their eyes and look through it quickly. For example, say a designer is at work on a concept for a new chair. The designer drafts the chair in 3D CAD, but isn’t sure if it makes sense at scale. With VR, the designer could view the chair

model at the right proportions, to scale. The designer would return to 3D CAD and modify the design based on its VR image. The ability to quickly switch from 3D CAD to VR without getting up or gearing up is the idea behind VR snacking; taking a little bite of virtual reality for design purposes. HP already has a number of headsets intended for mixed reality. Other companies also make these mixed reality headsets, including the Samsun Odyssey and the Acer from Microsoft. The Opera Glass will be designed to be lighter than these—thus the quick setup time and the name: just like slipping on a pair of glasses. It would also immerse users in a virtual environment rather than bring a virtual environment to their existing surroundings. It’s intended to smooth the shift from computer monitor to VR headset.

The glasses themselves actually resemble VR googles more than eyeglasses or opera glasses, and they’re perched on a desk stand rather than a stick you’d use to raise opera glasses to your eyes. But the goal is the same as that of those who want to see the opera close up. Raise your glasses to get a better (or in this case) VR view. Again, the glasses are still in the proof-of-concept stage. Engineers have a while to wait until “VR snacking” will become part of their workflow. The working prototype was on display at Autodesk University in Las Vegas. But the signs point to a series of hardware applications that will help engineers toggle between VR and CAD with only a few mouse clicks and without much thought. DW

HP Labs | www8.hp.com/us

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UNMATCHED POSITIONING PERFORMANCE HexGen® Hexapods by Aerotech are the next generation in 6 degree-of-freedom positioning HexGen® hexapods are ideal for large payload, high speed, ultra-precise positioning. The HEX500-350HL provides unmatched positioning accuracy (±0.5 μm linear, ±2.5 μrad angular) and positioning resolution (20 nm linear, 0.2 μrad angular). Simply stated, HexGen hexapods are the highest performance hexapods on the market. Contact an Aerotech application engineer or visit our website for more information on how Aerotech hexapods can improve your positioning application.

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Internet of Things

IBM, Siemens and the Charter of Trust

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Paul Heney, Editorial Director

At last month’s Siemens cybersecurity press meetings, journalists had the opportunity to get the perspective of researchers at IBM Watson’s Munich IoT operations center. The Center brings together developers, consultants, researchers and designers to drive state-of-the-art collaborative innovation with SMEs and start-ups, as well as governments, schools and universities and investors. Dr. Angelika Steinaker, CTO Identity & Access Management, IBM Security Europe, discussed the importance of identity and access management. According to Steinaker, “everything in security is related to identity” and this is of critical importance to everyone involved in cybersecurity. “If you talk about network segregation, and point security, CM, targets, everything is related to identity,” she stressed. She gave the example of a smart bulb located in a building. Whose bulb is it? Who can access it online to control it? While this seems innocuous enough, think of all of the stakeholders involved. Maybe one company owns the building. Another one has leased that building and its employees are working there. A third company is the facility manager. And yet another provides applications for building insights. So, let’s say that the building is equipped with an application to get insights on energy consumption, which has reduced costs considerably. Everyone’s happy. Until the leasing company’s CISO detects that someone has hacked their database through a smart bulb in a conference room. This brings to light (no pun intended) multiple questions — ones that aren’t necessarily so easy to answer:

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• Who is the owner of security? • How could this situation have happened? • Did the bulb have a Digital Identity? • How could it have been prevented? • How are stakeholders to be supported? Steinaker referenced the famous Peter Steiner New Yorker cartoon from 1993 that featured the caption, “On the internet, nobody knows you are a dog.” She said that today, she might instead caption it, “On the internet, nobody knows you are a bulb.” According to Steinaker, the principles in the Charter of Trust initiative can help to determine the owner and answer these questions. She said that the Watson IoT center in Munich is working with partner companies like Siemens to plan out best practices to avoid these sorts of scenarios. In her estimation, the first step a company should take is to establish Identity Assurance Requirements for device

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classes before setting up an IAM framework for IoT. Additionally, Identity Assurance may vary on the device class, type of application, strength of network, sensitivity of data, criticality of operations and impact of a potential compromise through unauthorized access. Other keys that a company should focus on, according to Steinaker, are:

1 Define an enterprise security and IAM architecture • Use a recognized method for an enterprise security and IAM architecture • Adopt a graded trust model for IAM capabilities • Design authentication and authorization schemes, based on risk models • Establish an appropriate organization by working across the business units 2

Integrate IoT implementation into an existing IAM framework • Establish an extensible identity lifecycle for all categories of Digital Identities, especially for on- boarding/registration • Create relationship mappings between all categories of Digital Identities • Implement more restrictive logic in identity management workflows • Integrate IAM with asset management repositories • Establish authentication and authorization procedures for local access or when only intermittently connected to the network • Install a privileged user management system so administrators accessing systems and devices are under control • Define privacy protections are required for different data categories • Integrate with an analytics solution “We think it’s very important to get these things in some sort of standard,” she said. “And this is why we here in Europe at IBM are also working together with ENISA, the European Network and Information Security Agency, which is similar to the NIS in the U.S.” “We still have organizational issues; process issues and technical issues, but this is a start ... standardization, framework, this is all needed. As far as the industry base, we can work in an organization like the Charter of Trust, and we need to get that in some sort of standardization. This will not happen tomorrow, it may be a 5- to 10year process.” DW

IBM | www.ibm.com

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Internet of Things

CC-Link IE TSN combines gigbit bandwidth with Time Sensitive Networking

T

The CC-Link Partner Association completed the specification for CC-Link IE TSN. This network was developed to meet future market demands and includes Time Sensitive Networking (TSN) technology. It can facilitate the integration of Operational Technology (OT) and IT. With IP and control communication technology, it assists flexible implementation with various types of equipment and achieves mixed usage of information communications. CC-Link IE TSN should improve efficiency and reduce time for the construction of smart factories using the IIoT. More details of the CC-Link IE TSN specification will be published on the CLPA Members Site. The CC-Link IE specification was released in 2007 as a 1Gbps Ethernet-based open industrial network and has expanded to motion and safety control after starting from general input/output control. It features high-speed and largecapacity control communication (cyclic data) that combines with non-control communication (transient data). The two can coexist with the 1Gbps bandwidth. Network errors are easy to diagnose. This network should bring a range of benefits to different industries since it is simple to build a system that controls and monitors a production site as well as collects and analyzes information. As IIoT systems have progressed to the practical stage in recent years, market demands for a range of devices implementing general purpose Ethernet communication have increased. Requests for high function motion control equipment and protocol implementation for various types of equipment have also increased. CC-Link IE TSN is a network that improves the performance and functions of the current CC-Link IE. Plus, it has increased openness through the use of TSN technology.

Features of CC-Link IE TSN • Flexible IIoT system construction • Adopts TSN Ethernet communication technology as a time sharing method • Enables collection of information from end devices by IP communication while securing real-time control communication • Faster time to market and reduced downtime • Easier network diagnosis by using general purpose Ethernet diagnostic tools compliant with SNMP • By means of time synchronization of compatible devices, it is easy to investigate the cause of problems • With the improvement of communication performance, CC-Link IE TSN can offer a best in class motion control operation cycle time of better than 31.25 µs • Segregation of high and low performance device communication, leading to optimized performance for all network stations and the system as a whole • Diversification of development methods • Offers hardware (ASIC and other device based) and software (protocol stack) development methods • Supports both 1 Gbps and 100 Mbps DW

CC-Link Partner Association (CLPA) am.cc-link.org

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Internet of Things

Software platform delivers end-to-end IIoT approaches

T

The Connected Data Solutions cloud software platform for Industrial Internet of Things (IIoT) applications is a software platform that is the most recent extension of Banner’s IIoT offerings. Paired with the company’s wireless and sensor product portfolio, the software creates a complete, end-to-end IIoT solution—from edge device to cloud. “Sensors have been the eyes and ears of the factory for decades, but Industrial IoT allows businesses to remotely access sensor data and use it in more meaningful ways,” said Matt Negaard, Director of IIoT Business Development. The software lets users easily and securely transmit data from connected devices to the cloud and immediately use that data to solve everyday challenges—from monitoring the productivity and efficiency of the factory to predicting machine maintenance requirements. Analytics and visualization tools provide actionable insight into operational and machine performance and help users make data-driven decisions.   Users can receive instant email or SMS notifications for important alerts.  In addition, users can store and download data for long term analysis to inform process improvements, optimize machine maintenance schedules, and more.  DW

Banner Engineering www.BannerEngineering.com

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For motion control innovation, Solution City never sleeps.

Remote I/O expansion for mobile automation

T

The X90 CAN bus controller makes it easier to connect remote sensors and actuators to mobile machinery. The scalable X90 control and I/O system allows efficient implementation of automation concepts for construction, agricultural and municipal vehicles. The standardized CANopen interface and multifunction I/O channels make the X90 bus controller versatile. All functions are configured in the control application using the B&R Automation Studio development environment. All products in the X90 family are designed for rugged use in mobile machinery. They can handle operating temperatures from -40 to +85°C (housing surface) and are resistant to vibration, shock up to 50 g, salt, UV light and oil. The housing provides IP69K protection. DW

B&R | www.br-automation.com

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2018_OEM_Magazine_20181031_印刷檔.pdf 1 2018/10/31 下午 01:18:31

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Internet of Things

EtherCAT Technology Group offers vendor-independent diagnosis interface

HMI or Diagnostic Tool

T

Diagnosis Interface

Master (Vendor 1)

Slave

Slave

Diagnosis Interface

Master (Vendor 2)

Slave

Slave

Diagnosis Interface

Master (Vendor n)

Slave

Slave

The EtherCAT Technology Group (ETG) specified a new vendor-independent diagnosis interface that

allows third-party tools to access diagnostic information from EtherCAT networks. The software-based interface can be implemented in controllers offered by any device manufacturer, which makes it an interesting feature to vendors of both master devices and diagnostic tools.

EtherCAT provides extensive diagnostic information at the hardware and software levels. It not only detects errors but precisely locates them. Diagnostic routines test the quality of the communication for internal errors in slaves, wrong cabling order, damaged cables or EMC interference. This includes bit errors as well as issues generated by loose connectors. The corresponding error counters are supported by all network slave devices. ETG has specified this user-friendly, vendor-independent diagnosis interface so that third-party diagnostic tools can work with any master implementation. No hardware changes are necessary, since an EtherCAT master is software-based, as is the interface. The interface is easy to implement with a small software footprint, so it is even suitable for embedded devices with limited memory. The standardized interface allows access to EtherCAT network diagnostic information for both hardware and software. Through

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the information provided by this new interface, diagnostic tools or HMIs can retrieve the EtherCAT network topology information, compare it with the expected configuration and detect communication interruptions and disturbances, as well as unexpected state changes. The specification ETG.1510 “Profile for Master Diagnosis Interface” enhances the “EtherCAT Master Classes” specification and extends the EtherCAT Master Object Dictionary already defined in the “Modular Device Profile” specification. Likewise, the access mechanism makes use of the already specified Mailbox Gateway functionality. Based on already existing standards, the new profile is therefore easy and straightforward to implement. DW

EtherCAT Technology Group www.ethercat.org

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Internet of Things

EtherCAT in 10-Gbits/s

E

EtherCAT G gigabit communication technology delivers the Gbit Ethernet speeds needed to support highly data-intensive applications. It is compatible with the globally established 100 Mbit/s EtherCAT standard, and offers the same familiar ease of use. In addition, the new branch controller model for EtherCAT G enables efficient operation of multiple network segments in parallel. EtherCAT G supports standard Ethernet transmission rates of 1 Gbit/s; its EtherCAT G10 counterpart is faster with data rates of 10 Gbit/s. The sharp increase in transmission rates beyond the standard 100 Mbit/s provided by EtherCAT increases the possible data throughput. With propagation delay times through devices as a limiting factor on the one hand, but boosted by the newly introduced branch model on the other, EtherCAT G can deliver a twoto-sevenfold performance increase, depending on the application. EtherCAT G and G10 are not meant to replace the EtherCAT standard based on 100 Mbit/s Ethernet. The new performance levels are intended as systemcompatible expansions. Though it is not a substitute for standard EtherCAT, EtherCAT G shares the same characteristics, yet achieves even higher transmission speeds without changes to the protocol or the EtherCAT master software. EtherCAT G provides capabilities that include built-in diagnostics, high-precision synchronization and telegram processing on the fly. It also conforms to the IEEE 802.3 Ethernet standard. EtherCAT and EtherCAT G can be combined within a heterogeneous network. This means that EtherCAT G slaves can operate in a 100 Mbit/s EtherCAT network, and vice versa. In both instances, EtherCAT G equipment falls back to the 100 Mbit/s rate. With the new EtherCAT G branch controller model, though, EtherCAT branches can be set up to enable the parallel operation of 100 Mbit/s segments within a 1 Gbit/s network through a conversion of transmission rates. For instance, the upcoming EK1400 EtherCAT

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G Coupler can create a branch that steps the data rate down from 1 Gbit/s to 100 Mbit/s, making available the wide range of standard EtherCAT Terminals for use as I/Os on an EtherCAT G network. Based on the branch controller capabilities of the EK1400, the 1 Gbit/s data rate on the EtherCAT G trunk remains unaffected. An advantage of the EtherCAT G branch controller system is that it minimizes propagation delays. The new CU14xx branch controller series is designed specifically to interconnect EtherCAT and EtherCAT G segments and enable parallel operation. This setup reduces signal propagation times, shortening communication and cycle times because telegrams coming back from a given segment travel straight from the branch controller to the master at the higher transmission rate of 1 Gbit/s, independent of other network segments. DW

Beckhoff Automation/EtherCAT www.beckhoffautomation.com

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customize verb, (used with object)

Edge systems turn data into action from edge to cloud

1. to build according to individual or personal specifications or preference. See haydonkerkpittman.com

According to Gartner, by 2022 up to 75% of enterprise-generated data will be created and processed outside a traditional, centralized data center or cloud. This figure is up from less than 10% in 2018. To turn edge data into insight for real-time action, it must be processed close to its source to avoid the latency, bandwidth and cost issues of sending the data to a remote data center. However, this opportunity comes with a set of unique challenges, including management of remote infrastructure, and the necessity to seamlessly connect sensors and industrial assets with IT applications at the edge. New software, technology and services for HPE Edgeline Converged Edge Systems – an infrastructure category that converges OT and enterprise-grade IT in one system, simplifies and accelerates the task. The HPE Edgeline Converged Edge System solutions speed the deployment and simplify the management of edge applications, enabling customers to act on the data generated by machines, assets and sensors from edge to cloud. Based on an open platform, enterprises can seamlessly integrate a broad ecosystem of applications and operational technology (OT) devices for edge deployments – driving efficiency and innovation in industries like manufacturing, energy, and telecommunications. The new products include: • HPE Edgeline OT Link Platform, an open platform that automates the interplay between operational technologies (OT) and standard-IT based applications at the edge to enable intelligent and autonomous decision making • HPE Edgeline systems management for the edge to ensure enterprise-grade reliability, connectivity and security • HPE Edgeline EL300 Converged Edge System with OT link and HPE Edgeline systems management for resilience against harsh edge environments for a range of industrial deployments • HPE Edgeline Field Application Engineering Services available from HPE Pointnext to help customers plan, build, and customize OT link-based IoT and cyber-physical systems. HPE Edgeline OT Link Platform is an open platform that includes: • HPE Edgeline OT Link Platform software, an open workflow engine and application catalogue, allowing customers to orchestrate components, data and applications via a graphical drag-and-drop user interface. The HPE Edgeline OT Link Platform integrates an ecosystem of third-party applications running from edge to cloud – including AWS, Google, Microsoft, SAP, PTC, GE, and more – to make insights from the edge available across the enterprise and supply chain. • HPE Edgeline OT Link certified modules, HPE-developed adapters that connect to a range of OT systems, enabling bi-directional, time-sensitive and deterministic control and communication, including high-speed digital input/output, CAN bus, Modbus or Profinet. APIs and SDKs for these adapters are available to the industry to facilitate third-party designs of OT link modules. OT link will also integrate FPGA modules to give customers flexibility to connect to any industrial input/output device. DW

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commonly applied across the OPC UA, EtherNet/IP and PROFINET protocols so all three can coexist on a common TSN-based network. • OPC UA pub/sub technology is implemented in a way that allows existing EtherNet/IP installations to support OPC UA devices. • OPC UA hardware requirements allow the protocol to be deployed on hardware platforms that are common in today’s EtherNet/IP components. • OPC UA software requirements allow the protocol to be deployed within current EtherNet/IP-centric software tools without significant changes to user

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motor running...

efficiently

A few tips for design and selection of induction and permanent magnet ac electric motor systems will make them more energy efficient.

E

Gabriel Venzin | ABM Drives Inc. | ABM Greiffenberger U.S. Subsidiary

Efficiency in motor designs is a more relevant concern than ever. With electric motors providing over 60% of all industrial power, efficiency is a key design parameter. Here we’ll look at some general requirements as well as more specific ones for permanent magnet ac (PMAC) motors, which hold for common industrial applications in a limited power range. To start, efficiency is defined as the ratio of delivered mechanical power to the supplied electrical power. An electrical motor that is 85-percent efficient converts 85 percent of electrical energy into mechanical energy. The remaining 15 percent dissipates as heat. Energy efficient electric motors use high-quality materials and optimized designs to achieve higher efficiencies. For example, more aluminum in the rotor and better slot-filling factor in the stator reduce resistance losses. Optimized rotor configuration and rotor-to-stator air gap reduce stray-load losses. Improved cooling fan design

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Exploded view rendering of an ac induction motor illustrating the housing, bearings and fan components.

provides motor cooling with a minimum of windage loss. Higher quality and thinner steel laminations in the rotor and stator cores allow operation with substantially lower magnetization losses. Finally, reduced friction losses result from higher-quality bearings.

Selection points for both induction and PMAC motors Optimizing the dimensions of rotor/stator laminations and the quality of steel used is key to improving performance

Hysteresis and eddy current losses together are called core losses. Around 20 percent of total losses are caused by eddy currents and magnetic core saturation. Eddy currents induced in laminations moving relative to a changing magnetic field cause significant power losses. Laminated stator cores reduce eddy current losses and are based on the quality, resistivity, density, thickness, frequency and flux density of the iron. Eddy current losses can be minimized with a higher number of laminations. Hysteresis losses are caused in the magnetic circuits when the flux is continually changing. The majority of flux-carrying material used in electric motors is steel used for stator and rotor cores. Minimize the flux density and core losses by reducing the thickness of laminations. Hysteresis losses are reduced by annealing better grades of steel for laminations to change the grain structure for easy magnetization.

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The special design of ABM’s Sinochron motor rotor with internal magnets leads to an almost ideal sine distribution of the magnetic flux. It’s designed for sensorless control mode, making it an alternative to servo drives.

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Reduce eddy current losses by increasing the resistivity of the steel with silicon, but silicon content increases die wear during stamping because it increases steel hardness. Steel crystals damaged during stamping severely degrade the magnetic quality of the affected volume. Annealing flattens the laminations and recrystallizes the crystals damaged during stamping, which extends one sheet thickness into the lamination. Use bath impregnation process for lamination, versus drip for optimum thermal management

Impregnating stators strengthens stator winding electrical insulation, protects against chemicals or harsh environments, and enhances thermal dissipation. Thermoset plastics including epoxies, phenolics, and polyesters are used for impregnating stators. ABM uses the bathing method whereby stators are immersed in resin for an extended period of time to assure optimum penetration and protection. Another impregnation method is called vacuum-pressure, which uses a tank that is evacuated first and then pressurized to achieve penetration into the stators. Driving out air pockets from the electric winding enhances the thermal conductivity of the winding. Design slots in the stator to maximize the volume of copper that can be inserted

Low stator winding mass causes up to 60 percent of total losses, so to reduce them the mass of stator winding must be larger which reduces electrical resistance. Electric motors that are highly efficient contain more than 20-percent extra copper compared to standard efficiency electric motors. The stator’s insulated electrical windings are placed inside the slots of the steel laminations. The cross-sectional area must be large enough for the power rating of the motor. In general, open or semi-closed stator slots are employed in induction motors. In semi-closed slots the slot opening is much smaller than the width of the slot, and winding is more difficult and time

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Due to high power density and optimized aircooling, this motor achieves outstanding efficiency.

consuming to manufacture compared to open slots. However, the air gap characteristics are better compared to the open type. The number of stator slots must be selected at the design stage because this number affects the weight, cost, and operating characteristics. The advantages of more slots are reduced leakage reactance, reduced tooth pulsation losses, and higher overload capacity. The disadvantages of more stator slots are increased cost, increased weight, increased magnetizing current, increased iron losses, poorer cooling, increased temperature rise, and reduction in efficiency. Use high grade/pure aluminum in the rotor die casting

Custom designed rotors can maximize starting torque, reduce conductor resistance and increase efficiency. Most induction motor rotors are squirrelcage designs. They are rugged, simple in construction and less expensive, but they have a low starting torque. Copper rotors increase efficiency but are difficult and expensive to manufacture.

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Tightening manufacturing tolerances allows optimum air gap between rotor and stator

The air gap is the radial distance between the rotor and stator in an electric motor for standard radial motors. An optimum air gap needs to be maintained for design efficiency. Air gap dimension involves the design of stator, rotor, motor housing, and bearings. All these affect the exact alignment of the stator and rotor axes. Use copper windings that meet DIN EN 13601 and UL Norm standards

The European standard DIN EN 13601 specifies copper and copper alloys for general electrical purposes including dimensions and tolerances, tensile test, hardness test, bend test, electrical resistivity test. It also specifies characteristics of coppers for electrical purposes including the preference for oxygen-free or deoxidized coppers which may be heat-treated, welded or brazed without the need for special precautions to avoid hydrogen embrittlement which causes cracking. For global compliance, UL determines that magnet wire complies with IEC 60317. Magnet or enameled wire is an DESIGN WORLD

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General selection guidelines The motor selection process involves some basic considerations. For starters, verify the application requirements. Then, what torque and speed is needed when and how often? What is the duty cycle? What are the ambient conditions such as temperature and pressure? Even the most efficient motor will not perform to its utmost efficiency if used for the wrong application. Many of the electric motors discussed here are used for gearmotors, a combination of a gear reducer and an electrical motor. A gearmotor delivers high torque at low speed. In short, gearmotors take motor power and reduce its speed while magnifying its torque. Gearmotor duty cycles do not only impact the motor performance rating, e.g., a continuous duty cycle S1 motor will provide a higher output if it’s used at an S3 intermittent duty cycle, but also especially for gearboxes used in extraordinary applications where torque peaks and system shocks are possible. For such situations, it’s critical to carefully determine what duty cycle and what peaks/shocks per a specific time period are experienced so the engineering team of the motor/gearbox OEM can select and recommend a suitable drive system. A good start is to review data on past extreme temperature and or pressure conditions in which the application will be operating and any other unique conditions that may be relevant to the design. Always inform the motor OEM if your application is being used in extreme conditions – this can be a game changer.

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electrolytically refined copper or aluminum wire that has been fully annealed and coated with one or more layers of insulation. ABM, for example, uses wires with a total of 12 insulation coats. Typical insulating films in order of increasing temperature range are polyvinyl, polyurethane, polyester, and polyimide up to 250 °C. Thicker rectangle or square magnet wire is wrapped with a high-temperature polyimide or fiberglass tape. Use of more copper, larger conductor bars and conductors increases the cross-sectional area of stator and rotor windings. This lowers resistance of the windings and reduces losses due to current flow. A high-efficiency electric motor will usually have 20 percent more copper in the stator winding. Design housing for best cooling

The electrical efficiency of motors has improved so much that the power drawn by cooling fans has become a larger percentage of the total losses. Optimization of cooling fan dimensions involves using the minimum power for the fan, while providing adequate cooling. The optimal fan design may result in a 65 percent reduction in fan power requirements. An important design feature is the clearance between the blade and the housing. The space between the housing and the fan blade should be as small as possible to prevent turbulence and decrease backflow. A cool motor runs more efficiently. To obtain the best airflow, optimize the cooling fan and fan shroud design. Assuring a tight bond between the stator and motor housing provides the best cooling performance. Select low-friction bearings suited for operating speeds

Ball or roller bearings are used in high-efficiency electrical motors. They consist of an inner and outer race and cage containing steel or ceramic rollers or balls. The outer race is attached to the stator and the inner race to the rotor. When the shaft rotates, the element also rotates and the friction of the shaft rotation is minimized. They have a long life and maintenance costs are low. High precision application allows the smallest air gap possible. Thermal contraction and expansion can affect shaft and housing fits as well as internal bearing clearances. Power output governs shaft size and bearing bore. Load magnitude and direction determines bearing size and type. Consider additional forces such as unsymmetrical air gaps causing magnetic

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SINOCHRON PMAC motor efficiency is more than twice compared to standard asynchronous motors under partial-load. It’s made possible by a continuously excited synchronous motor, which operates with practically no rotor losses.

pull, out-of-balance forces, pitch errors in gears, and thrust loads. For bearing-load calculations consider the shaft as a beam resting on rigid, moment-free supports. Ball bearings are more suitable for high-speed applications than roller bearings. High-speed factors include cage design, lubricant, running accuracy, clearance, resonance frequency, and balancing. Knowing the ambient temperature range and the normal operating temperature range will help determine the most effective lubrication method for the bearing: oil or grease. Normal operating temperatures for gearmotors considered here range from -25 to 40 °C. Synthetic grease has good performance properties over a wide range of temperatures. Grease allows simplified maintenance, cleanliness, fewer leaks, and contaminant protection. Bearings need a minimum load, so rolling elements rotate and form a lubricant film rather than skidding, which raises operating temperatures and degrades lubricants. Allow a minimum load equal to about 0.01 times the dynamic radial-load rating for ball bearings. It’s especially important when bearings are approaching 70 percent of recommended ratings. Use a quality balancing machine, high standards and balance at the operational speeds of the motor application

Noise and vibration can result when the center of mass does not co-exist with the axis of rotation. Balancing has limited effect on efficiency but impacts operating noise and life expectancy that

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This illustration shows the special design of the SINOCHRON PMAC motor rotor laminations and the imbedded magnets that allow a sinusoidal motor motion.

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is also important for maximum use of resources. Bearing vibration readings are normally taken on three planes – vertical, horizontal and axial. Vertical vibration may indicate a mounting problem. Horizontal vibration may mean a balance problem, whereas axial vibration may indicate a bearing problem. Balancing at operational speeds is important because unbalance can also be caused by centripetal forces at the bearings.

Additional design criteria for PMAC motors PMAC motors are a growing alternative to ac induction motors, which for decades have been the workhorse of almost any electrical motor application. PMAC motors preserve the

reliability and simplicity of the ac induction motor while offering higher efficiency, synchronous operation, and the opportunity to use a smaller frame size. PMAC motors replace the magnetic field induced in the conductors in the rotor with permanent magnets, usually made from alloys of rare-earth metals, giving them much lower electric resistive losses than ac induction motors because no electric current is induced in the rotor. In place of mechanical commutation, a control system is required to determine which coils are supplied with current to produce the maximum torque. Magnetic fields generated by rare-earth PMAC motors can deliver the same torque as ac induction motors with a smaller, lighter motor. Select PMAC motor size to allow operation in partial load area for best efficiency

An electrical motor that is 85% efficient converts 85% of the electrical energy into mechanical energy. The remaining 15% dissipates as heat.

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Energy savings from PMAC motors depend on the number of service hours, motor size, and motor loading. PMAC motors nearly always maintain higher efficiency – no matter the speed or torque compared to ac induction motors and makes them an attractive alternative to induction motors in variable-speed applications. By substituting existing line-powered three-phase electric motors with PMAC motors, energy savings of 20 to 35 percent can be expected. Optimize design of rotor laminations to show a sinusoidal magnetic field

For example, ABM synchronous motors with highperformance permanent magnets come with a sinusoidal flux distribution as well as Electro-MotiveForce. Stator windings, for distributed windings, are normally identical to asynchronous motor windings. It results in lowered vibration, noise and maintenance cost as well as increased overall performance. Selection of rare earth versus ferrite (ceramic) magnets

Neodymium rare earth, samarium cobalt magnets or ferrite (ceramic) magnets are used in PMAC electric motors. Rare earth magnets are two to three times stronger than ferrite or ceramic permanent magnets but are more expensive. Samarium cobalt magnets are optimal for high-temperature applications because of their high energy density, 250 to 550 °C temperature resistance, small decrease of parameters due to temperature increase, and oxidation protection. The selection of samarium cobalt or neodymium as an electric motor magnet is based on operating temperature, corrosion resistance and required performance. A low-grade neodymium magnet may begin to lose “strength” if heated above 80 °C. Highgrade neodymium magnets operate at temperatures up to 220 °C. Ferrite or ceramic magnets have won wide acceptance due to their strong resistance to demagnetization, exceptional corrosion resistance, and low price. Magnetic losses occur when operating at temperatures above 250 °C, but are recovered when the magnet is brought down to a lower temperature. Cold temperatures of -40 °C may result in permanent losses of magnetic strength unless the circuit has been designed for such extremes. PMAC motors require inverters

PMAC inverter drive units can be loss-free in no-load operation/standstill. New motor design combinations offer advantages in powering conveying equipment, escalators, spooling machines, compressors and

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January 2019

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traction drive units. By substituting existing line-powered three-phase drive units, energy savings of up to 30 percent can be expected. The characteristic profile of PMAC drive units makes them well suited to drive pumps and fans that operate continuously. No additional components, like encoders, are needed. Up to 25 percent smaller footprint allows machine designs to be more compact. The motors have excellent control behavior and combined with a sensorless drive controller unit, have excellent true running even at low speeds and impressive dynamics at impulse load and speed variations. Select an inverter that can provide sensorless operation

Standard PMAC drives can “self-detect” and track the rotor’s permanent magnet position. This is critical for a smooth motor start and also allows for optimum torque

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production, which results in optimum efficiency. Lack of position or speed sensor reduces the cost and increases reliability of a drive system. Programming and optimization of inverter

The importance of programming the controller settings for a specific motor to attain optimum efficiency is becoming more and more important with the everincreasing efficiency regulations. Choosing manufacturing partners

When choosing partners during a machine build, remember that there are two methods for choosing an electric motor source. Either pick a standard motor that might or might not fit a specific application or choose a competent motor partner to engineer and manufacture a motor that fits the application exactly.

Standard motor solutions are suitable if a design engineer doesn’t have the time or engineering resources to have a custom version engineered — or if it needs a quick setup. New modular approaches to design and construction let manufacturing engineers get reasonably priced custom motors even in modest volumes. No matter the approach to motor selection, be sure to continually improve the design/drive system by comparing predictions of performance with measurements. Then use the result of the analysis to improve the next iteration. DW ABM Drives www.abm-drives.com WHAT DO YOU THINK?

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Choosing

the right stage actuation for dynamic-metrology applications When measurements are made to discrete product on the fly, it’s key that the motion system minimize error and correct for the rest. Brian Handerhan | Business development manager | Life sciences Patrick Lehr | Product manager | Precision mechanics Electromechanical & Drives Division | Parker Hannifin Corp.

D

Dynamic metrology is the collection of data on objects traveling on moving machine axes. It’s increasingly common with laser-based inspections and spectrometry, and primarily for semiconductor and electronics manufacturing that uses line scanning of discrete product during various processes. Life-science applications such as cell analysis or DNA and gene sequencing — which necessitate high data-collection throughput — also employ dynamic metrology. Yet another application is in precision laser cutting. Because the stages carrying the product are in motion during measurements, they must exhibit minimal linear errors, Abbe errors, and planar errors. Sources of these errors abound — and include linear-slide and assembly machining inconsistencies, bearing inconsistencies, friction, deflection, thermal fluctuation, inconsistent feedback, and mechanical windup.

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For linear-positioning devices, industry quantifies such error in eight different ways. Abbe errors occur in pitch, yaw, and roll directions; they are significant contributors to accuracy and repeatability and are quantified with angular measures. Linear errors in the X, Y, or Z directions relate directly to the accuracy and repeatability and are quantified with linear measures In contrast, planar errors occur in X, Y, or Z direction and contribute directly to the adjacent axis in a multi-axis system. These are also quantified with linear measures.One special note: Accuracy is affected when the measuring point rides at some distance from stage … and total error is higher when the point of measurement is more distant from the stage. In such applications — where the point of interest is some distance from pitch, yaw, or roll points — minimizing Abbe error is most

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critical. Design engineers must account for such magnification of such errors when specifying linear stages for dynamic metrology applications.

Motion control complements mechanical accuracy Also necessary for dynamic metrology is tight control over motionstage speed. Error in the form of unexpected acceleration and deceleration (as velocity ripple) makes the accurate and consistent collection of results in dynamic-metrology setups impossible. Scanning applications in particular need good velocity control or risk poor data collection (relative to expected position) and blurry results. Causes of velocity ripple include deviations in the mechanical drivetrain; leadscrew, or pulley pitch variations; and friction changes

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EIGHT DIFFERENT ERROR SOURCES IN LINEAR-POSITIONING DEVICES Abbe errors include yaw, pitch, and roll.

Linear errors occur on X, Y, and Z.

Z Planar errors affect adjacent axes ...

Yaw (pan)

Pitch (tilt)

Straightness

Roll Flatness

Y

X

There are several ways to minimize torque ripple at stage axes: Install a high-resolution linear-feedback device on the actuator; install a very low subdivisional error (SDE) encoder on the axis motor; or employ a drive controller with a high servo-update rate.

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More details on all three error types can be found at blog.parker.com; search on dynamic metrology. Keeping errors to a minimum means minimizing their sources — including machining and bearing inconsistencies, friction, deflection, thermal fluctuation, inconsistent feedback, and mechanical windup.

over the travel stroke. Other factors that can cause velocity ripple include accuracy error in the feedback device, a current control limitation in the motor drive; a PWM frequency instead of a linear amplifier; and sub-optimal servo algorithms and control update rate. Holding velocity stable during dynamicmetrology processes can be done in a few ways. One option is to use linear-motor actuators for a quick-response drive and velocity corrections sans drivetrain pitch or friction problems. Another is to install a very low sub divisional error (SDE) encoder — for which position errors occur between hard counts of the encoder. Otherwise, linear feedback on the actuator maybe in order. Another technology helpful to dynamic-metrology is a drive controller with a high servo update rate — capable of quick velocity measurements and corrections.

Applying stages actuated by linear motors for dynamic metrology Most actuation of high-speed dynamic-metrology applications is through stages driven with linear motors — ironless linear motors in particular. Because the linear motors in such stages directly DESIGN WORLD

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ERROR FROM EACH DEGREE OF FREEDOM AFFECTS ACCURACY We measure position over the total linear travel.

m

Z

30

m

10

Y

m

10-mm arm in Z direction

m

100-mm arm in Z direction

X

Consider two operations that include a point of measurement some distance from the linear stage. Total error is higher when the point of measurement is more distant from the stage.

couple to the load, there’s minimization or even total elimination of the backlash, efficiency losses, and positional inaccuracies of belt and ballscrew-driven arrangements. What’s more, linear motors are typically more compact than other drivetrains. That makes for smaller machines with higher stiffness — for lower positional errors and a

lightweight design capable of high speeds. Linear-motor actuators also hold the tightest control over high speeds … even necessitating consideration of encoder subdivisional errors and servo-position control loops in some cases. Where these are addressed and optimized, linear motors can avoid velocity-ripple issues to deliver quick

actuation. At reasonable commercial cost, engineers can optimize systems to achieve following errors to 200 nm at aggressive dynamic-metrology speeds. But to minimize velocity ripple, the engineer must have the application’s speed and sampling rate before specifying encoder resolution and servo sampling rate.

SETTLING TIME TO CONSTANT VELOCITY

VELOCITY

CONSTANT VELOCITY ± PERCENT OF NOMINAL

Velocity control is critical for dynamic metrology applications because the latter depends on smooth speed for accurate and consistent measurements.

SETTLING TIME

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L i n e a r

M o t i o n

LINE-SCANNING DESIGN: STRAIGHTNESS AND FLATNESS UNI-DIRECTIONAL

BOTTOM AXIS

TOP AXIS

This plots the error from two stage axes. Bottom-axis target accuracy is ±4 µm; actual accuracy is far better than that — at ±1.2 µm. Top-axis target accuracy is ±4 µm; actual accuracy is far better than that — at ±0.8 µm.

Consider one application for which a design engineering team in the semiconductor market performs laser line-scanning. Assume the process depends on flatness and straightness — with errors not exceeding ±4 µm over a 300 x 300-mm travel zone. Here, wide-base monolithic stages in X-Y systems from some manufacturers can maintain high stiffness for minimal flatness and straightness errors. Consider another line-scanning application and assume scanning frequency of 100 Hz. Also assume velocity ripple must be below ±2% at stroke speeds of 10 mm/sec. That means position error must stay within ±0.2 mm/sec/100 Hz — or 0.002 mm per 0.01 sec. So here, the stage actuator needs an encoder with resolution exceeding allowable position error … a 2-µm encoder at least. Plus the servoupdate rate must be at least tenfold the required correction rate (0.01 second times 10 = 1-msec update rate). Here, only stages with precision encoders and certain servo drive and controller combinations can hold velocity to within requirements.

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In fact, only linear-motor actuated stages can meet the critical specifications of dynamic metrology. Look for suppliers of these systems that supply laser-interferometer test reports to confirm each stage’s ability to outperform other drivetrain mechanisms and deliver metrologylevel performance. DW Parker Hannifin | solutions.parker. com/LP=12738

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Better Communication standards for motion and robot systems As more automation systems incorporate robots and cobots, good communication among system elements is critical.

In a recent interview with Brendan O’Dowd, general manager

Deterministic Ethernet is increasingly

for industrial automation at Analog Devices,

a part of these communications and

we heard about new devices — even to the chip

is coming to the floor in an array of

level — that allow better integration of robotics

standards.

into motion designs and machines for automation, as well as the latest developments on industrial communication systems.

Lisa Eitel | Senior Editor

Design World: What new developments in automation do you consider most significant? O’Dowd • Analog Devices: Our company has been around for 50 years. For some time, we’ve investigated the systems into which our parts go … to create better solutions for these designs. For example, sometimes engineers asked us to reduce power

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consumption. Usually there was something specific prompting the question — such as thermal dissipation being an issue. We learned that it’s not always the posed question needing addressing — but something related to it. So we began using technology and our silicon experience to solve problems in new ways. On connected motion and servos and drives, several parts are involved in the sequencing. There’s the processor — the system brains — and the PWMs driving the signal … as well as the isolated DESIGN WORLD

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gate drivers (IGBTs) … and the measurement of the currents returning — for a complete control-loop algorithm. We’ve worked to optimize many of these. But from a system point of view, communications have become more critical — and deterministic Ethernet is increasingly a part of these communications. Even in factory control and process automation where 4-to-20 mA and fieldbuses have reigned for a long time, Industrial Ethernet is coming to the floor … in an array of standards.

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Our company has been around for 50 years. For some time, we’ve investigated the systems into which our parts go … to create better solutions for these designs. 108

Design World: Our industry sees a lot of proprietary standards — all good for certain things — but not always able to work together. O’Dowd • Analog Devices: They’ve been successful … but now as we

need higher speeds, there’s migration towards unified standards — with the Time Sensitive Networking (TSN) collection of standards currently leading. In fact, nine or 10 different IEEE standards are part of that TSN bundle. They cover things such as ingress policing (for the prevention of traffic overload conditions on a network) and other network functions. We expect TSN standards to supersede most existing industrial Ethernet protocols. Design World: But it’s unlikely that those invested in existing industrial Ethernet networks will abandon what they use … and those networks’ unique benefits — especially for realtime functionality. O’Dowd • Analog Devices: Yes — and with the growing tide of robots

and especially cobots, real-time functionality is absolutely critical. So we’ve invested in multi-protocol solutions … because it’s okay if you’re Siemens, Rockwell, or Beckhoff, with all your equipment the one standard you sponsored — but many smaller players must deal with these different standards. For them, it means unless they’re designing for an all-Siemens factory or an all-Beckhoff factory, they must support multiple standards.

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Design World: What kinds of products support all major protocols?

Design World: How does that relate to robots and the new wave of cobots in automation?

O’Dowd • Analog Devices: Some of

O’Dowd • Analog Devices: The latter

our Ethernet switch ICs have built-in TSN features to support several IEEE TSN standards. We aim to offer compatible updates to next-generation TSN as those standards are finalized. As any latencycontrolled Ethernet standard, TSN standards allow synchronization of the Media Access Control (MAC) physical interface on different boards at different parts of the system. For a drive, motor, or robot, actual motion is controlled by PWM output. The time synchronization then has to make its way through the communications stack and through the motion-control stack and out to the PWM output — to drive the actual gate drivers to time the motor. So many view TSN from the Ethernet point of view — and focus on getting that synchronization down to the boards … a significant problem itself. But they leave the rest of the problem to individual designers. That’s why we bring motor-controland motion-control signal-change domain expertise to our Ethernet work. We aim to deliver system solutions, and not just pieces of silicon. The key point is when a semiconductor supplier can apply domain expertise to silicon design, it is possible to solve wider system-level problems.

are about sensing and understanding the environment … with many offerings today being very much in the analog domain. But using technologies borrowed from other fields — such as radar and LiDAR from automotive, for example— will come to expand the array of system-level domains in robotics. People often ask why we’re acting more as system suppliers and not acting as a traditional component supplier. Well, it’s because we’re working to be relevant at higher levels — by leveraging our domain-level expertise and newer expertise in robots, motor control, condition monitoring, and Ethernet. Design World: Just to be clear for engineers who don’t usually think of design work at the chip level — would you explain what you mean by domain in this context? O’Dowd • Analog Devices: Sure. There are

IC technology silos — for A-to-D converters, performance amplifiers, processors, and power supplies, for example. We also have experience silos for automotive, motor control, and process control. Some we developed internally from work with customers on applications. Some we’ve hired into the team — for example, in robotics and motor control design — to get views that are different from

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The fido5200 REM switch (one version of the fido5000 series) supports industrial Ethernet protocols such as EtherCAT.

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a silicon designer’s view. The challenge is that silicon designers think in terms of what they know — transistors and fab processes and so forth — whereas motor-control designers think in terms of PWMs, and current feedback, and control loops. So having them work together for weeks, months, and years spurs richer conversations and solutions that wouldn’t have been created otherwise. That’s what constitutes domain-level design.

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Design World: You’ve been gracious in not mentioning specific Analog Devices products for such flexible functionality. But may I ask what those are? O’Dowd • Analog Devices: Our single piece of silicon — the

fido5000 REM Switch IC — is configurable with a binary download we supply. That means engineers can setup for an EtherCAT version of a field instrument … or a PROFINET version … or Ethernet IP version … and it’s the same hardware, just with a different binary download. With less designing and debugging, that in turn reduces time to market and models in inventory … and boosts assurance that what gets shipped to the end user will be the right version, as it’s just a software image. In this way, the fido5000 REM Switch IC is a flexible part — with TSN protocols ready to go and pin-for-pin replacement compatibility. Design World: Many proprietary offerings provide realtime functionality. Does your new offering adhere to IEEE standards for that?

Need a Sensor for a Unique Requirement?

O’Dowd • Analog Devices: Our Deterministic Ethernet

Technology Group (DET) director Jordan Woods also represents us on the standards bodies — so we can sell standards-ready silicon from day one. Even when standards aren’t finalized, we have customers evaluating our ICs’ functionalities to deliver on what’s coming. Design World: What in the motion and robotics markets are driving innovation? O’Dowd • Analog Devices: Motor control and robotics are driving

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the need for higher bandwidth. Some in factory automation resist the idea of needing GbE — accepting 100 Mb as enough. But they’ll need higher bandwidth in the future. Even in residential homes, the number of Internet-connected things has risen dramatically. Factories are no different — and high-bandwidth items such as cameras and radar (for time-of-flight measurement and positioning, for example) are leading the charge. Such technologies are key to knowing where people are around a robot, for example. Having a work cell’s cameras execute auto recognition on workpieces … or artificial intelligence — these too demand big bandwidth. What’s more, some design engineers are frustrated with accommodating lots of standards. These two things are driving the trend towards standard TSN. So I predict the big players will continue to support legacy equipment with proprietary standards — even while next-generation standards are still

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Design World: Do you offer software for configuring your chips?

Design World: How does this relate to another connectivity-enabled function — that of condition-based machine health monitoring?

O’Dowd • Analog Devices: We

sell preconfigured chips — and supply the binary … already certified with the standards body — so the chips are ultimately pre-certified to EtherCAT or PROFINET or to the applicable standard. That minimizes work for the engineer. But higher-level software — that lets engineers configure networks — that’s not something we offer yet. At the moment these offerings are tied to more integrated designs. Design World: On the topic of more connectivity between motor-driven machine axes and robotics — what’s particularly innovative here? O’Dowd • Analog Devices: We’ve

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supplied lots of I/O for PLC-based control … analog out and in … digital out and in. We see such controls moving to higher data rates as well — and I think TSN standards will become very prevalent here. But at Ethernet IP becomes standard in the factory everywhere — and not just in parts — it will replace some 4-to-20 mA and fieldbus connections. So while motor controls and drives will spur higher bandwidth, maybe not factory automation but certainly process control — including oil and gas and pharmaceutical industries — will increase use of lower bandwidth over longer distances. Design World: Another area of interest is network security.

O’Dowd • Analog Devices: We’ve been doing MEMs vibration sensors for 25 or 30 years … with most airbags in the world controlled with our MEM sensors, for example … and first-generation Nintendo Wii consoles as well. With our motion and vibration-sensing expertise, now we’ve begun exploring ways to use MEM sensors in motor control … as a lot of information can be gained from monitoring motors over time to understand their states — as bearings wear or loads begin to have issues, for example. We’ve all heard stories of that one guy who can hear problems or lay his hands on a machine to detect issues — or skillfully use probes for measuring various characteristics. In short, there is now a way to have this level of monitoring using technology rather than a highly skilled “machine whisperer” … DW Analog Devices | www.analog.com

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O’Dowd • Analog Devices:

Standard approaches to using PCs and IT infrastructure with firewalls and certificates doesn’t work well at the factory level. After all, firewalls between machines could quickly bring down production. So configuration and setup must be well engineered. Our security company

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How to design a

scalable communications infrastructure for IIoT sensor networks

Engineering a scalable network architecture does not come without challenges. There are many factors to consider when choosing the

By 2023, the number of Industrial Internet of

right “last-mile” connectivity. Here

Things (IIoT) active connections is predicted to surpass

are six key factors.

four years. IIoT applications like remote monitoring and

46 billion, representing a growth of 140% over the next predictive maintenance require massive sensor networks that can continously capture granular data from assets and their functioning environments. With the explosion of data acquisition points and traffic at the edge, industrial companies are in critical need of a scalable machine-to-machine (M2M) communications architecture.

Albert Behr | CEO and founder, Behr Technologies Inc.

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Engineering a scalable solution from the beginning minimizes the need for expensive modifications in the future, thereby securing long-term return-on-investment (ROI). However, building such an architecture does not come without challenges. There are many factors to take into consideration when choosing the right “last-mile” connectivity. www.designworldonline.com

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I n t e r n e t

Mesh Topology

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Star Topology

The network topology will influence what will be required from a planning and administration effort. For example, mesh topology can be more sophisticated to manage than the star topology. Often times, mesh networks require installing extra devices that act as routers, not to capture important data, but to achieve the desired coverage.

6 considerations for designing IIoT systems

1

Network capacity

Network capacity refers to the amount of traffic a network can handle at a given time. High network capacity allows for seamless and reliable system operations as the number of end nodes continuously grows. Self-interference caused by confined radio resources is the number one issue that dampens network capacity in wireless IIoT networks. Devices deployed within the operating range of each other and sending data using the same frequency band vie for the use of that shared radio resource. The higher the device density and the more frequent the data transmission in a network, the more likely multiple messages are sent simultaneously. This leads to packet collisions and eventually, data loss. Often, self-interference is further complicated by a light-weight, asynchronous medium access control (MAC) protocol such as ALOHA, adopted by many low-power wireless technologies. While reducing complex overheads and, ultimately, power consumption, purely asynchronous systems entail uncoordinated communication among end nodes, which heightens the collision likelihood. Efficient use of the finite radio spectrum, also known as spectrum efficiency, is key to remedying self-interference and improving overall capacity. This can be achieved by low bandwidth use of a signal and DESIGN WORLD

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short radio “on-air” time – the time a packet travels from source to destination over the medium. A well-designed radio technology with high spectrum efficiency can offer a network capacity of millions of daily messages using only a single base station.

2

Inter-system interference

Intersystem interference is another major threat to effective operations and the scalability of IIoT communications networks. This problem is often caused by co-existence of multiple radio signals in the same license-free industrial, scientific and medical (ISM) frequency bands. The 2.4 GHz ISM band is the most widely used frequency in legacy industrial applications and systems and therefore, the most congested one. Wireless technologies using this band are susceptible to significant electromagnetic interference from various sources like Wi-Fi hubs, Bluetooth-enabled cell phones, microwave energy, RF lighting, industrial heaters, and welding

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Today, there are a number of wireless communication technologies, each with a different level of scalability and suitability for massive IIoT sensor networks.

By 2023, the number of Industrial Internet of Things (IIoT) active connections is predicted to surpass 46 billion, representing a growth of 140% over the next four years.

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equipment. If all of the 2.4 GHz channels in your industrial facility have already been saturated, they aren’t recommended for other IIoT deployments. Using less crowded sub-GHz ISM bands, for example the 902-928 MHz, can partly mitigate the interference problem. Nevertheless, these bands are now gaining increasing popularity as well. To best tackle near-future exponential traffic in the shared spectrum, system designers should equip their IIoT architecture with a robust, interference resilient wireless technology. Frequency Hopping and channel coding (i.e. Forward Error Correction) are common techniques adopted to improve system robustness.

3

Network setup, management and maintenance

Managing ten sensors and a thousand sensors are two totally different situations. The theoretical network capacity may sound impressive, but if it involves outrageously complex network configuration and management, manufacturers most likely won’t find the necessary IT competence to scale. The choice of network topology can decide what will be required from a planning and administration effort. For example, mesh topology, widely adopted by short-range wireless technologies, can be more sophisticated to manage than the star topology of wide-area solutions. Often times, mesh networks require installing extra devices that act as routers, not to capture important data, but to achieve the desired coverage. Redundancy is hence an intrinsic part of these networks, which can complicate management activities.

January 2019 www.designworldonline.com

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Battery life is another critical aspect when it comes to device maintenance and scalability in practice. Maintenance costs account for a substantial proportion of Total Cost-of-Ownership in wireless sensor networks. Imagine how expensive and cumbersome it would be with a thousand field sensors deployed remotely and the need to replace batteries every few days.

4

Communications security

Security comes up in all IIoT conversations, and unless the communications technology is equipped with a versatile, well-proven cryptographic scheme, secure data transfer will be an enormous challenge in everexpanding IIoT networks. The Advanced Encryption Standard (AES) is the globally validated standard for message encryption to protect data confidentiality, integrity, and authenticity against eavesdropping and other malicious attempts. Typically, a cipher-based message authentication code (CMAC) can be computed based on AES cipher blocks. Thanks to its low power, high speed, and high throughput, the AES algorithm is highly suitable for wireless sensor networks.

5

Interoperability

Scalability and interoperability essentially go hand-in-hand, and the key to long-term interoperability is standards. Standards establish consistent and transparent technical models for third-party developers to easily integrate the communication protocol into various IoT devices and application platforms. An important aspect of a scalable system is its ability to adapt to upcoming technological trends and flexibly evolve with corporate needs. In this context, implementing an industry-standard protocol allows for dynamic future hardware and software changes in the IIoT architecture without incurring downtime or undue delays.

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6

Network Longevity

Manufacturers in search of a scalable IIoT architecture should also consider the longevity of the communication technology. Longevity reflects stable operations of the IoT system over years without foreseeable disruption due to network shutdowns. Expensive industrial assets and critical infrastructure often have a long lifespan (several decades), however certain wireless technologies are already on the verge of phasing out. System designers who choose to ignore the impending sunset of these technologies will probably find themselves having thousands of disconnected devices a few years down the road. Aligning network and device longevity should be a core pillar in a company’s long-term IoT strategy. Evaluating different communications options Today, there exists a plethora of wireless communication technologies, each with a different level of scalability and suitability for massive IIoT sensor networks. High bandwidth technologies like cellular (3G, LTE, etc.) and Industrial WLAN (based on IEEE 802.11 standards) are mainly intended for data-intensive, time-sensitive applications such as security cameras, voice communications, industrial routers, and supervisory control and data acquisition (SCADA) systems. On the downside, the extremely high-power requirement makes them fail to support large-scale, battery-operated sensor networks. Cellular technologies additionally raise considerable concern over network longevity. By 2018, most major global telecoms have announced their 2G shutdowns with the 3G sunset currently rolling out. Short-range technologies based on IEEE 802.15.4 standards like Zigbee and WirelessHART are more optimized for power consumption due to lower data rates (e.g. 250 kbps). Operating in the 2.4 GHz band, their physical range is limited to a few tens of meters due to high rates of signal attenuation and fading. To improve coverage and expandability, these technologies are mostly deployed in a mesh topology. Nevertheless, the relaying mesh functionality can easily shorten battery life, since devices must constantly “listen” for messages that need to be relayed through them.

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Scalability of IEEE 802.15.4-based mesh networks can be constrained by several factors. First, though theoretically, nodes can be added as much as needed, inflating complexity in network planning and management – as discussed previously, limits their capacity in practice to a few hundreds of devices. As these networks often cannot scale beyond medium-range applications, their deployments in geographically dispersed industrial campus are hampered. More importantly, IEEE 802.15.4 technologies are exposed to substantial inter-system interference in the congested 2.4 GHz airways that potentially confines network expansion. Leveraging sub-GHz frequency bands and very low data rates to reduce path loss and improve receiver sensitivity, low power wide area networks (LPWAN) offer excellent range, coverage, and data propagation. Long wavelengths allow LPWAN signals to travel over kilometers and deeply penetrate through walls, buildings, alongside other “heavy” physical obstructions. Therefore, they provide more reliable data transmission than 2.4 GHz signals in structurally dense, rebar environments like mines, refineries, and other manufacturing facilities. In terms of battery life, LPWAN can be suitable thanks to a combination of star topology, deep-sleep mode, and lightweight MAC protocol. Note that both excellent range and power efficiency in LPWAN are achieved at the cost of data rates. These networks are therefore best-suited for condition monitoring, facility management, and predictive maintenance IIoT applications wherein latency is tolerated. Scalability greatly varies across LPWAN systems due to their difference in network capacity and interference immunity. What’s more, not all LPWAN solutions are based on rigorous industry standards and some of them lack a versatile, valid security scheme like AES. So far, only two camps of LPWAN technologies have been standardized by global Standard Development Organizations and are thus verified for their Quality-of-Service and long-term scalability. One is cellular LPWAN including NB-IoT and LTE-M implementing 3GPP standards. The other is MIOTY – an emerging technology implementing the new ETSI standard on Low Throughput Networks – TS 103 357. As a key takeaway, scalable IIoT architecture requires a communications solution that can support continuous network expansion without compromising system performance. For batterypowered sensor networks in structurally dense, wide area industrial settings, LPWAN provides the most viable scalable solution. With multiple technologies available today, system designers should thoroughly consider critical factors that determine scalability – from both technical and operational viewpoints. DW

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Simulation bearing software improves design Rolling bearings are vital in rotating equipment. They support shaft loads, reduce friction, and provide shaft location and system rigidity. In theory, bearings can outlast systems and equipment. In reality, this is rarely the case. Operating conditions will always influence the expected service life of a bearing. Here’s how simulation software can help improve bearing design.

For decades ISO-standardized and advanced industry bearing life calculations have helped

inform choices on the road to properly selecting a bearing. As a starting point, designers traditionally have considered a bearing’s basic rating life, referenced as the calculated L10 fatigue life, to determine how long the bearing can operate.

Travis Shive Applications Engineer SKF

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But bearing failures in the field more often than not will result from “root causes” instead of sub-surface bearing fatigue. While the failed bearing becomes the victim, in most instances the failure is due to abnormal surface stresses from less-than-ideal operating environments. The adverse conditions potentially shortening a bearing’s service life can include excessive misalignment, insufficient loading, overloading, and excessive running speeds, and many others. These issues present looming challenges for designers throughout the bearing selection process, leading to this question: How can the actual performance and longevity of bearing arrangements in real-world operating conditions be predicted with a relatively high degree of certainty? Powerful simulation software tools have been engineered for the job.

January 2019 www.designworldonline.com

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Such modeling and analysis simulation tools help designers evaluate the design of bearing arrangements and their field performance based on application requirements and conditions. This analysis optimizes bearing arrangements, accelerates the design process, reduces testing times, and supports bearing selection. Evolving technologies Enabling technologies to model and analyze bearings and bearing systems have evolved dramatically over the past decades, thanks to advances both in technology and computing power. Viewed historically, the models in the 1960s and 1970s focused primarily on two rigid bodies in contact and were compared with mathematical theories and

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experiments. This led to the development of a complete bearing model in the 1980s, in which many contacting elements were combined in a single model (bearing rings and rolling elements). But these first models were restricted to steady-state calculations and lacked an accurate rolling element retainer (bearing cage). Subsequently, specialized test rigs were constructed to validate such unknowns as cage forces and bearing dynamics. Today’s advanced simulation tools have come a long way from the early days ­— offering successive levels of capabilities resulting in highly accurate representations of bearings and complete systems. A single-shaft bearing simulation tool exemplifies the available software packages for use by designers across industries. An

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A single-shaft bearing simulation tool enables verification of bearings for a wide range of industrial applications.

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•• •• M e c h a n i c a l •• intuitive software program guides users through a series of “walk-through” steps and simplifies calculations required to correctly select and verify the most appropriate bearing for a wide range of industrial applications, including fans, pumps, compressors, electric motors, gearbox shafts, and other rotating equipment. An overview of the multi-stage modeling and analysis process: Application modeling — An intuitive, stepby-step interface models an application with common system components, such as shafts, bearings, housing, gears, lubricant, spacers, and springs. Modeling and analysis simulation tools help designers evaluate bearing arrangements and aid in selection.

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Adding operating conditions — Speed, loads, lubrication, and shaft and housing fits can be added to the application model, even allowing speed and load conditions to be entered as a combined load cycle.

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Running calculation — Once a model is built,

designers can run a single load analysis or a full load cycle analysis, depending on machine operating conditions. Also, a bearing preload optimization analysis can be conducted. Viewing and reporting — Calculation results

can be populated with a comprehensive range of performance output parameters, including bearing fatigue life, bearing load, loaded zone, contact stress, bearing displacement and misalignment, friction, bearing defect frequencies, and shaft deflection. The output can be viewed in various graphical charts and 3D animation. Reports are created automatically and are exportable for sharing the results. Step-by-step process Building a complete bearing system model with a single-shaft simulation tool begins by designing a shaft and then adding the common components via a user-friendly “drag-and-drop” feature. Once a shaft is defined, bearings can be easily integrated consistent with how the bearing would be mounted on the shaft and in a housing. With gears, designers can define the type (bevel, helical, hypoid, spur or worm) and then are prompted to enter gear geometry and input power to the gear, which automatically reconciles different gear forces. As for the remaining components for “drag-anddrop” onto the shaft, springs introduce the ability to preload bearings against a ground (such as the housing) and preload against another bearing. (This is useful for applications where springs are used to locate a bearing or meet minimum load requirements for applications, such as pumps, compressors, and electric motors.) Spacers establish defined endplay values, which assists in applications with back-to-back or face-to-face bearing arrangements. The second primary step in the modeling process encompasses applicable boundary conditions. Shaft rotational speed, radial and axial forces, power input (gear), a moment load, and gravity can be added to the model. Similar to the components, force, power input, and moment can be applied by “drag and drop”; the other boundaries are simply an icon click. All applicable boundaries can be varied in an “Analysis Variations” portion of the program (except for gravity, which is separately applied to allow the study of applications in horizontal or vertical positions).

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Bearing simulation software tools offer practical technologies to evaluate performance ahead of system production, explore new design alternatives, accelerate the design process, and help contribute toward the goal of maximized rotating equipment performance.

Engineering Solutions for Clutches & Brakes

The third primary step in the modeling process targets lubrication and fits. Designers can define the lubrication method (grease, oil bath, or oil spot), oil viscosity, and contamination levels. For fits, an icon click opens a sub-window allowing modification of shaft and housing fits, initial internal bearing clearance, and inner and outer ring temperature values – all impacting the operating bearing clearance. After a model is completed, analysis and reporting follow. An option is provided to run a single data set analysis (single analysis) or to run several conditions (load-cycle analysis), based on the defined operating boundaries. Another option provides a time weight portion to determine bearing service life over several different operating conditions. Analysis output can be formatted and delivered in data tables and visuals – and designers at the outset can create a preferred template set-up for the reporting. Other distinct tables can communicate details about re-lubrication intervals, operating clearance, bearing defect frequencies, and gear forces. Visual plots and animations can be generated, too.

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Regardless of a tool’s level of sophistication, however, an experienced bearing manufacturer well-versed and equipped in simulation engineering can help with initial training and throughout the entire process. In some cases, simulation software programs will open doors for designers to select bearings directly from a manufacturer’s catalog or provide access to bearing databases updated with the most current bearing options. Bearing simulation software tools offer practical technologies to evaluate performance ahead of system production, explore new design alternatives, accelerate the design process, and help contribute toward the goal of maximized rotating equipment performance. DW SKF | skf.com

126 January 2019 www.designworldonline.com Mechanical (SKF) 1-19_V4.LL.indd 126

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M e c h a n i c a l

Why spring choice matters

Springs may not be at the top of a designer’s mind when working on an application, but they are essential in many applications. The sizes and types available vary greatly, and their choice is influenced by application parameters and industry requirements.

Healthcare and medical, agricultural, and automotive industries can choose from an amazing array of springs. But it’s important to choose the right spring for the specific application. The following are commonly used spring types:

David Payunk Product Manager, Springs Trelleborg Sealing Solutions

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Belleville washers, also known as coned-disc springs, conical spring washers, disc springs, Belleville springs, or cupped spring washers, are a conical shell that can be loaded along its axis either statically or dynamically. Compression springs are usually of a coil type and offer resistance to a force that often compresses a spring. Constant-force springs exert a constant force over their range of motion and do not obey Hooke’s law. Generally, they are constructed as a ribbon of spring steel that rolls up when relaxed. Extension springs, also known as tension springs, are designed to store energy and exert a specified pull force when extended to a specific length.

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Power springs, also known as clock springs, store and release large amounts of rotational energy in the form of torque. Torsion springs work by torsion or twisting. When twisted, they exert torque in the opposite direction proportional to the amount they are twisted. Lastly, wave springs, also known as coiled wave springs, are made up of pre-hardened flat wire in a process called on-edge coiling or edge-winding that add a wave to give them a spring effect. Automotive Springs Springs are used throughout a vehicle’s interior, exterior and within the engine. Compression springs are used in anti-lock brake systems and fuel injectors along with

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locks, pumps, and valves. The most common form is a straight cylindrical formed from round wire, but they are also used in other complex shapes, such as hourglass, conical, barrel, square, ovate, rectangular, or with reduced ends that are produced from round or flat wire. Extension springs are used in what is termed foundation brake components — the brake-assembly components at the wheels of a vehicle. Power springs are used in retractor mechanisms such as those found in seatbelts while torsion springs are used as couplings between concentric shafts such as in a motor pump assembly. They are typically found in single coil or double coil forms. Coil springs are often found in heavier trucks, specifically on the front suspension between the upper and lower control arms.

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Compression springs are used in anti-lock brake systems and fuel injectors along with locks, pumps, and valves. The most common form is a straight cylinder formed from round wire, but they are also used in other complex shapes, such as hourglass, conical, barrel, square, ovate, rectangular, or with reduced ends that are produced from round or flat wire.

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•• •• M e c h a n i c a l •• Torsion springs are used as couplings between concentric shafts such as in a motor pump assembly and are typically found in single coil or double coil forms.

These springs are suitable to carry heavy loads and are therefore also used within the air brake assembly. Belleville washers are used in clutch and brake mechanisms as well as in transmissions. Healthcare and medical springs Within the healthcare and medical industry, springs can be found in devices as diverse

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as x-ray machines, bed lift mechanisms, and drug infusers. There is a multitude of different types of springs to accommodate countless applications. While some springs dampen force and perform a pushing action, others oppose extension by pulling themselves back together. Compression springs are used in prosthetic limbs to enhance performance or

when a squeezing action is needed, such as in a surgical stapler. Extension springs are used in stretchers, surgical lights, and many small handheld devices. Constant force springs, either motor type (drum take-up) or extension type (strip end connection) are often found in surgical instruments and MRI machines. Wave springs are sometimes specified in place of conventional round wire compression springs. Generally, wave springs occupy 30-50% of the compressed height space of comparable round wire springs, offering more deflection with the same load specifications. They are used in drug delivery devices, especially EpiPens or insulin pens, as well as in support prosthetics and orthotics. Many of these healthcare and medical applications are hygienic and require production in cleanrooms. Also, shoulder-to-shoulder engineering can be instrumental in helping device makers to go from initial design through to market.

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should also be able to offer a range of finishes and surface coatings to enhance application performance. Agricultural springs In agricultural applications, springs are found in many types of farming equipment from seed meters and harvesters to irrigation systems, mowing equipment and tractors. They need to be reliable in extreme temperatures, often have to accommodate working effectively in dirty environments and handle pressure loads. Compression springs are needed to support a variety of the load requirements of an agricultural setting and are used widely in irrigation, such as in pop-up sprinkler heads. Spring clips and pins are used to support farmers in properly attaching tractor hitches. Specialized springs and wire forms are found in hydraulic systems, planters, and cutters. Tines are heavy wire forms on machines that work the field soil. Torsion springs, extension springs, and other types of springs are often used in combination with various gas-powered handheld lawn equipment. Springs play an essential role in the automotive, healthcare and medical, and agricultural industries, impacting performance and helping provide optimal operating scenarios. However, it is vital that the correct type of spring is chosen from the wide variety of types on the market. To ensure the best performance in every case, though, each application should be investigated, and in most cases, a custom solution will be required. DW Trelleborg | tss.trelleborg.com

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P n e u m a t i c s

Proper air

preparation for automated machines Available in many combinations, filters and regulators are a must-have on any machine. Other devices to perform functions such as energy isolation, lockout tagout and lubrication should also be considered. Chip McDaniel | AutomationDirect

All pneumatic motion requires clean and dry air with sufficient flow and pressure. The process of filtering, regulating and lubricating compressed air is known as air preparation, sometimes shortened as air prep. Manufacturing plants include air prep at centralized compressors, and additional air prep is beneficial at each machine’s pointof-use. The air prep system — often referred to as the FRL after the filter, regulator and lubricator that is often included in the assembly — is essentially the breathing mask on a machine, its personal protection equipment. Therefore, it is a must-have system, and it consists of many components. This article will discuss the components used in machine air prep systems and show how each is used, Figure 1.

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Operating pressures Air prep systems are typically assembled inline and come in a variety of port or body sizes. Most air prep systems fall in the range of 1/8-in. to 1-in. NPT female port sizes, with some exceptions. These systems are often modular in design, so when specifying an air prep system, it’s importation to match like-size devices for ease of assembly and use of accessories. Generally, the pressure range of each pneumatic device is 20 to 130 psi, to match up with the common supply air pressure in a manufacturing facility, which is between these values. While a lockout valve may have a pressure range of 0 to 150 psi, other air prep devices such as filters, regulators and soft-start/dump valves require a minimum operating pressure to

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Figure 3: As the name implies, this NITRA combination filter/regulator combines both filter and regulator functions into a single, space saving unit. | Courtesy of AutomationDirect

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P n e u m a t i c s

The air prep system not only protects the machine from debris and moisture, it can also protect operators from hazards by providing a means to safely remove pneumatic energy from the machine.

activate internal pilot and drain valves. The minimum operating pressure may be as low as 15 psi and as high as 35 psi, depending on the device. Manual shut-off relief valves Crushing, pinching, cutting, amputation and other injuries due to unexpected or automated machine motion often occur due to an employee’s failure to safely disable and isolate energy sources, and lockout/tagout the machine before performing service or maintenance work. Pneumatics is one of those energy sources, and because of the possibility of injury, OSHA and ANSI have important regulations regarding lockout/ tagout control of hazardous energy and prevention of unexpected startup. The air prep system not only protects the machine from debris and moisture, it can also protect operators from hazards by providing a means to safely remove pneumatic energy from the machine. The manual shut-off relief valve or a pneumatic isolation lockout valve provides removal of motion-causing pneumatic energy, along with a means to lock the valve in the off position as part of a lockout/tagout procedure. It shuts off upstream air pressure

and relieves downstream air pressure to an entire machine or zone, Figure 2. Its oversized exhaust ports provide a quick pressure release, which can be very loud, so suitable silencers (mufflers) should be used, especially if ear protection is not required in the area. These shut-off or lockout valves are typically either the first component connected to plant air at a machine, or the first valve following the FRL components. These valves use either a manually-rotated knob or push-pull activation, and both configurations can be locked out with a padlock. To aid visual identification, the knob should be red in color to indicate a safety device, like an emergency stop button. It’s important to note that, even though the shut-off valve relieves air pressure, trapped air (energy) may still be present downstream from the air prep unit. The use of center-closed, three-position valves is just one of several examples of this, and it’s the designer’s responsibility to provide and document a manual or automatic sequence to remove such air for safe maintenance of the machine.

Figure 1. This air prep unit has many NITRA pneumatic components including filter, regulator with digital pressure switch, distribution block,lubricator, soft start/dump valve and manual shut off connected to a modularvalve manifold. | Courtesy of AutomationDirect

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P n e u m a t i c s

Figure 2: Rotating the red knob on this NITRA manual shut-off valve counterclockwise safely removes air from this conveyor zone eliminating pinch hazards during maintenance.

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Pneumatic air filters Filters are a critical part of an air prep system for removing both particulates and moisture. These filters use either a centrifugal or a coalescing design. The centrifugal types remove particulates and some moisture, while the coalescing types remove more water and also oil vapor. A dryer/refrigerator unit, not discussed here, may be required to remove larger amounts of moisture, and is installed just downstream of a plant air compressor. A standard industrial air filter typically includes a replaceable 40-micron filter element mounted inside a polycarbonate bowl of various body sizes to accommodate different flow rates,with a metal bowl guard often included. For stricter filtration requirements, 5-micron filter elements are available. Finer, micro filters are available to remove particles 1 micron and below for special applications, but these require a courser filter upstream. Depending on usage, periodic replacement of a filter may work, but a downstream pressure switch — or better yet, a differential pressure switch

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measuring pressure across the filter, with its output monitored by a PLC — can be used to detect a clogged filter. Regardless of the design, the filter can remove particulates, water and oil vapor — all of which are trapped in the filter — or accumulate at the bottom of the bowl as a solution that can be drained through a manual, semi-automatic or automatic drain. Manual drains require manually opening a drain plug to remove the accumulated liquid. Semi-automatic drains open each time compressed air is shut off, and an automatic drain opens when air is shut off or when the liquid in the bowl activates a float. The type of drain used depends on the plant supply, application and environment. Very dry or low use equipment will work fine with a manual drain, but proper maintenance requires fluid level checks. Semi-automatic drains will work well in machines that are often turned off with air pressure removed. However, if air is always on or if water accumulates quickly, an automatic drain is the best choice.

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P n e u m a t i c s

Regulators A regulator is often “set and forget� when used to supply compressed air at a consistent pressure to a machine, with a typical adjustable pressure range from 20-130 psi. Some processes operate at the low end of the pressure range, so lowpressure regulators are available to provide an adjustable range from zero up to around 60 psi. Regulators are also available to provide instrument air at common pressures, typically in the 3-15 psi range. "Gear precision grade" Because supply of air at constant pressure is critical to machine operation, a regulator with a locking pressure adjustment Gear precision grade knob is required. An integral pressure gauge should also be included to help Gear precision Grade quickly identify actual air pressure. Another useful device is an adjustable 0 1 2 3 4 5 pressure switch mounted downstream of the pressure adjustment device and N4 N5 N6 N7 N8 N9 8 monitored by the machine controller. 4 5 6 7 8 9 Pressure regulators have an input and output that must be connected 73) correctly. The air must flow from input to output, and installing the regulator 13 12 10 9 8 7 backwards will cause it to malfunction. 14 12 11 10 9 8 13 12 11 10 9 The8 regulators should also have a relieving operation in most applications. 11 10 10 9 8 With a7relieving operation, if the pressure setpoint is reduced at the regulator, the regulator output will reduce downstream air pressure. able :

Figure 4: Total air prep systems are about half the size, weight and cost of systems assembled from separately purchased components. | Courtesy of AutomationDirect

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A combination filter/regulator includes all the features of a standalone filter and regulator in a single, space-saving device, Figure 3. Precision combination filter/ regulators are also available with more precise pressure-regulating capability. Lubricators A lubricator adds lubrication as an oil mist to the pneumatic air supply instead of removing contaminates as a filter does. This lubrication can increase speed and slow wear in pneumatic devices such as air-operated hand tools including grinders, impact wrenches and torque drives. It also reduces leakage in operating components by sealing the rods, although it is not required to oil the seals on most modern pneumatic devices such as valves, cylinders, rotary actuators and grippers. Lubricators are available in many port sizes and the lubrication rate can be adjusted. To assist with maintenance, a sight gauge is included, and the oil can be added while the devices are under pressure in most cases. The mist level must be properly adjusted and the oil level maintained, and the proper oil (typically light viscosity oil such as SAE 5, 10 or 20 with rust and oxidation inhibitors added) must be provided. Also, the device in need of lubrication must be close enough to the lubricator for the oil mist to remain suspended in the air. Too much oil may cause

an oil mist in the facility, along with oil puddles and slippery floors. Soft start/dump valves The soft start/dump valve is an important device for operator safety, and typically includes a 24 Vdc or a 120 Vac solenoid controlled by an emergency stop, or by guard or light curtain safety circuits. It dumps motion-causing pneumatic energy by shutting off upstream pressure and relieves downstream pressure when de-energized during a safety event. When the circuit is reenergized, the solenoid gradually increases air pressure downstream. This keeps tooling from moving too quickly and banging at startup. This valve is mounted downstream of the FRL, typically feeding air to motion-causing solenoid valves. The dump valve exhausts pressure quickly, so a high-flow muffler should be used to attenuate the sound. An adjustable flow control is provided to control how fast the air pressure returns to the set pressure. Air prep accessories All the pneumatic air prep devices above are provided with a mounting bracket for stand-alone applications, or the mounting accessory can be purchased separately. Air prep systems are often modular in design which allows individual shut off, filter,

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regulator, lubricator and soft start/dump valves to be easily field assembled with other components. Assembly brackets and adapters are often required when connecting these modular devices to create a combined unit. These adapters include U-, L-, and T-brackets, each of which has one or more mounting tangs. Air distribution blocks are also available for installation between pneumatic components. Conclusion Total air prep (TAP) systems are available as an alternative to specifying all the air prep components separately. These all-in-one systems include the filter, regulator, shut off/dump valve, soft start, electric shut off, pressure switch and indicator. A TAP is about half the size, weight and cost of an air prep system assembled from separately purchased components, Figure 4. With a better understanding of pneumatic air prep components and their use, both machines and operators can be protected. To summarize, a manual shut-off relieve valve and soft start/dump valve is required to control, isolate and remove compressed air from the machine or system. As the air flows to the system, a filter, regulator and lubricator are used to prep it for use. DW AutomationDirect www.automationdirect.com

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Novel axial flux designs now coming off the drawing boards could become the primary means of powering future generations of electric vehicles.

Innovative electric motors If you build an electric motor whose rotor and stator are flat, not cylindrical as in ordinary motors, you are devising what’s called an axial motor. Axial motors, as their name suggests, produce flux in an axial, rather than radial, airgap. The resulting envelope for the motor can be discshaped. This short, stubby profile makes axial motors good candidates for use in cramped quarters such as the recess of an automotive wheel hub.

Leland Teschler | Executive Editor

Axial flux magnetic machines can produce a higher torque than a conventional motor of the same size. The reason is that magnetic flux in a conventional radial motor scales with the square of the diameter, but flux in an axial machine scales with between the second and third power. So the bigger the motor, the larger the advantage of an axial design.

The axial magnetic motor from Magnax in Belgium sandwiches the stator windings between two rotors carrying rare-earth magnets. The motor design is called yokeless because each stator winding (visible in the near-by close up) sits in the magnetic field of the rotor magnets without the use of metal pieces forming a yoke.

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E l e c t r o n i c s

Motors with an axial form factor have gotten a lot of attention in recent years as the move toward electric vehicles has fostered a need for small, compact powertrains. New axial designs have been proposed for use in drones, robotics, and other applications where spaceefficient power is a benefit. It can be useful to study specific axial designs as a way to understand how these motors operate. One of the more interesting examples of the technology is what’s called an electrostatic motor, devised by C-Motive Technologies Inc. Rather than use magnetic attraction to spin a rotor, the C-Motive machine uses an electric field. In addition to the advantages of an axial design, the C-Motive electric field devices are lighter and smaller than magnetic devices of similar output parameters.

Motors that use an electric field for motive force are built around the idea of spinning capacitors rather than the spinning inductors of conventional electromagnetic designs. Energy conversion in conventional magnetic motors takes place in the air gap between the rotor and stator. In contrast, energy conversion in electric field-powered motors takes place in a dielectric material. Electric field-powered motors have only become practical in recent years with the development of dielectric materials having a high electric permittivity. Their novel architecture combined with other advances lets these motors store 45,000 times more energy than possible previously. The main factor determining the efficiency of electric power mechanisms for energy conversion is the density of the electric or magnetic energy stored in the electromagnetic or electric fields. The fact that electric field machines can be smaller and lighter than magnetic versions can be explained partly by the configuration of magnetic force lines. They form in the heavy electric steel in the motor. The magnetic circuit is used for power transfer, but energy conversion takes place in the air-gap itself between the stator and the rotor. And the air-gap volume accounts for a relatively small part of the machine’s volume. The electrical steel takes up most of the space.

Radial flux, conventional motor

Energy conversion takes place in air gap between rotor and stator

Cross section: Simple axial flux machine Rotor Flux path Usually an air gap in magnetic machines

(

Stator

Axial motor design: Flux flows in the axial direction between commutated inductive or capacitive segments.

A key advantage of an axial-flux motor is the large amount of motor area devoted to energy conversion compared to that of a conventional radial-flux motor. In radial-flux machines, energy conversion takes place in the cylindrical air gap between the rotor and stator. Power scales up with the square of the motor diameter. But power scales up in an axial-flux motor at a rate somewhere between the second and third power of motor diameter thanks to the larger energy conversion area.

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E l e c t r o n i c s

In contrast, electric field machines have power lines starting and ending in the rotor and stator plates. Energy conversion takes place in the gap between the stator and rotor. But the rotor-stator gap takes up a sizable part of the volume of the whole machine. Assuming that the specific energy is equal for both electric field and electromagnetic machines, the machines based on the electric field effect will be significantly smaller. Because dielectric materials are much lighter than ferromagnetic materials, machines based on the electric field effect will be also lighter and likely less expensive. To understand how a motor can be devised using capacitors, consider a round capacitor with each of its two plates divided into two or more sectors. The rotor sectors have a constant electrical charge of alternating polarity. The stator sectors have timevarying ac charges. When a voltage is applied across this capacitor, there is an attractive force between the stator and rotor sectors. If the rotor and stator sectors are offset from one another, the attractive force establishes a moment. The moment rotates the rotor until the sectors coincide.

Principle of operation Segmented capacitor motor

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The concept of a capacitive motor can be understood by visualizing two segmented discs rotating near each other, separated by a dielectric. Each segment of the disc forms one plate of a capacitor. The motor shaft can be rotated by energizing one set of plates that are offset from one another, then switching the polarization as the plates approach complete overlap in a manner that resembles commutation in conventional dc motors.

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Visible on this stator from a C-Motive electrostatic motor are the segments making up the stator capacitor plate. The rotor capacitor plate would look identical though it would be attached to the shaft that rotates. C-Motive says the stator and rotor capacitor plates are on conventional FR4 printed circuit board material. The large number of plate segments are indicative of the large number of poles that characterize the company’s motors.

At the moment the sectors coincide, the polarity of the applied voltage is switched between the positively and negatively charged sectors. The action is analogous to that of commutation for dc motors. If the number of plates rises, the motor torque increases. The torque of a capacitive machine operating this way can be calculated by differentiating the energy stored in the capacitor electric field. Motor designers can boost the torque the motor can provide by increasing the number of rotor-stator capacitors. Of course, as the rotor spins, the capacitance between the rotor and the stator varies in proportion to how much their surfaces coincide. But the moment of this capacitive machine is constant and independent of the rotor angle. The speed of the capacitive motor is a function of the supplied power. Shades of Ben Franklin The idea of a capacitive motor created this way is quite old – Ben Franklin devised one in the 1750s. But the concept has only recently been realized in motors practical for real use. One such design comes from C-Motive Technologies Inc. in Madison, Wisc. C-Motive calls its design an electrostatic motor. It’s biggest innovation, according to C-Motive CEO Justin Reed, is a dielectric in the form of a liquid that lies between the capacitor plates that make up the stator and rotor. “People have assumed the viscous drag of a liquid dielectric would be too high. But we’ve figured out a way to manage the viscous drag,� Reed says. “The resulting electrostatic motor produces high levels of torque that are superior to

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E l e c t r o n i c s

Prototype electrostatic axial motors from C-Motive. The company says the motors are under consideration for a number of applications. C-Motive also says the typical drive circuit for these motors would be relatively ordinary medium-voltage, lowcurrent inverter.

what rare-earth PM motors produce on a torque-per-kilogram basis.” Reed also says it is relatively easy to cool the C-Motive motor because its dielectric fluid conducts heat to the enclosure. This factor additionally lets the motor be sealed if necessary, to handle harsh environments with no degradation of its cooling capacity. Reed thinks the operational sweet spot for the electrostatic motor will be applications in the 2,000-rpm range and below. “For all intents and purposes the only loss in the machines is the viscous drag. The drag will keep them out of areas that need 15,000 rpm motors,” he says. “The slower it spins, the more efficient it becomes. That’s the opposite of any electromagnetic motor.” Reed says the electrostatic motor is in the development phase with the first full prototype expected early next year. The prototype will be

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E l e c t r o n i c s

a NEMA 56 frame servomotor meant as a demonstrator. Companies in a number of industries have expressed interest in seeing the prototype, he says, for applications such as wheel hub motors in off-road vehicles, three wheelers, and aerial drones. Larger aerial drone uses are particularly well-suited for the motors, he thinks, because they are characterized by slower-spinning props that would otherwise require conventional motors that could become quite heavy. Axial axioms Another example of an axial motor design comes from Magnax in Belgium. Its axial flux design is based on a proof-of-concept originally built at the University of Ghent in 2009. The motor uses a stator disc carrying windings that is sandwiched between two rotor discs carrying magnets. There are small air gaps between the stator and two rotors. The stator has a special design that

is termed yokeless because it includes iron teeth carrying windings but without using an outer iron section to hold the teeth. This gives the motor a shorter flux path. The windings around the teeth are positioned such that there are no overhanging loops that don’t contribute to generating flux. Thus in the Magnax axial motor, 100% of the windings are active. Ordinary radial flux motors might only have 50% of their winding wire contributing to the generation of magnetic flux, adding extra resistance and causing heat build-up. Magnax further boosts motor efficiency through use of rectangular-section copper wire. The point of the yokeless design is to help maintain a constant air gap between the stator and rotor. Other magnetic axial motors tend to generate enough force between the rotor and stator discs to actually deflect the rotor against the stator and cause a failure.

As Magnax describes it, the yokeless axial flux design is such that the two rotor discs constantly put equal and opposing forces onto the stator disc. The rotors connect directly to one another via a shaft ring, so the magnetic forces cancel each other out leaving no loads on the internal bearing. To help cool the motor, Magnax brings the windings into direct contact with the outer aluminum casing for better heat transfer. Magnax says its motor is highly scalable, ranging in diameters from 15 cm (~6 in.) to 5.4 m (~13 ft) and perhaps beyond. The motors can also be slotted in next to one another to run in parallel. Typical applications might include EVs, aircraft rotors, and in large-diameter, high-torque, lowRPM wind power, hydroelectric and wave power generation. DW References C-Motive Technologies Inc., www.c-motive.com Magnax, www.magnax.com

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The gap between design and 3D print is closing quickly thanks to software that streamlines the process of designing for 3D printing.

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To additively make a three-dimensional part,

you need more than a 3D printer and .STL or equivalent program. Now that additive manufacturing (AM) is becoming a viable means of production, developers are filling in the gaps between design and build with software that offers a range of additive manufacturing features. These features are all aimed at smoothing the path from design to production. If successful, these steps will help additive manufacturing gain wider acceptance as a production tool. Here’s a look at some of the available programs.

AMFG launched a software platform that uses artificial intelligence to automate additive manufacturing production. The AI-driven software addresses issues of manual and unscalable production processes by providing manufacturers with complete AM production automation.

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AI-driven software for industrial 3D printing London, UK, based AMFG, a leading provider of automation software for additive manufacturing, launched a software platform that uses artificial intelligence to automate additive manufacturing production. (AMFG was known as RP Platform). AMFG’s AI-driven software addresses issues of manual and unscalable production processes by providing manufacturers with complete AM production automation, including: Scheduling automation Printability analyses Post-processing automation Machine analytics

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Autodesk collaborated with Authentise

to deliver integrated workflow for Additive Manufacturing. Authentise released an integration that makes seamless use of Autodesk’s Netfabb software with Authentise’s additive workflow management tools possible.

Although AM technology is maturing, it can be difficult to predict if a part will be 3D printed as expected, especially for inexperienced users.

“Our vision is for our software to enable autonomous additive manufacturing,” says Keyvan Karimi, CEO of AMFG. “While 3D printing has the potential to transform manufacturing, we’ve seen the lack of a scalable production process as a key barrier. Our software closes this gap by incorporating machine learning algorithms to provide an endto-end solution for the 3D printing manufacturing process.” “Ultimately, we’re creating an autonomous manufacturing process for industrial 3D printing. For us, this means taking manufacturing to a new era of digitalised production.” The Post-Processing Scheduling software helps users plan and allocate the resources needed to fulfill any additional post-processing requirements. Completed builds are automatically moved to the platform’s dedicated Post-Processing page, where post-processing actions can be allocated to the appropriate production jobs, prioritized and marked as completed when done. For full traceability, all the date and time of all part status updates are logged centrally in the system. A beta version of the company’s digital QA management tool allows users to import part documentation, such as reports, data sheets and 3D images, and compare these specifications to the physical, 3D-printed part for quality checking. Tools that take advantage of 3printing Recent updates to Autodesk Fusion 360 further the use of cloud capabilities, generative design, and additive manufacturing. These updates include a collection of tools that work inside Autodesk’s

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Inventor (including Nastran In-CAD, HSM, and a nesting utility). Also new is a suite of specialized toolsets available with AutoCAD, and a cloud-based technology offered with Fusion 360, Fallon said. The Fusion 360 integrated workspace includes a hybrid manufacturing experience that combines advanced additive and CAM capabilities in a single workflow. For example, Autodesk Netbabb and Fusion 360 connect with Autodesk generative design technology and HP Multi Jet Fusion 3D printers. “Incorporating the unique voxel-level capabilities of HP Multi Jet Fusion with Autodesk generative design unleashes new levels of creativity, speed, and quality from prototyping all the way to production,” added Michelle Bockman, global head of 3D Printing commercial expansion and development at Hewlett Packard. Autodesk is working to expand the manufacturing for generative design to include 2- and 2.5-axis machining, meaning designers will be able to specify those machines when working on a generative design. Simulating metal 3D printing EOS and German start-up Additive Works are collaborating to enhance the additive manufacturing process of metal materials. Their cooperation focuses on the simulation based pre-processing software Amphyon, DESIGN WORLD

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which simulates the AM building process before it actually takes place, highlighting and optimizing possible problematic areas of the part to be built. Shape accuracy, surface quality, and build productivity and stability can be increased. Dr. Nils Keller, CEO, Additive Works states: “Although AM-technology itself is mature, it can be difficult to predict if a part will be 3D printed as expected especially for inexperienced users. So when a part is manufactured with issues, such as surface defects, it means a waste of machine time and material costs.” Amphyon predicts possible build challenges and automates pre-processing steps. The program orients all steps along the “ASAP” principle (Assessment –Simulation – Adaption – Process), a workflow for Direct Metal Laser Sintering job preparation. Consisting of several different software modules, Amphyon addresses the application areas, part assessment, support optimization, and process simulation. On the assessment stage, an examiner module evaluates the geometry of the part and assesses all possible build-up orientations. The ideal orientation depends on the application in terms of build time, support volume, post processing efforts and part deformation. Amphyon software automatically finds the best part orientation in the build chamber of the 3D printing system. On the simulation stage, there are two modules available: The Support module and the Mechanical Process Simulation (MPS) module. With the Support module, optimized support structures are generated automatically. These structures support the part on the build platform and define the process results. Amphyon’s optimization routines adapt the support perforation as well as the interfaces between part and support based on the calculated process loads. Time and costs of manual support generation can be saved, as well as support material. The MPS module offers a fast and intuitive way to simulate process mechanics and to calculate distortions. The software can compensate such distortions by exporting and building a “predeformed” STL file. The simulation capabilities help assure process stability and design accuracy of the application. To ensure an easy and accurate simulation, key EOS metal materials are integrated into Amphyon software and calibrated with regard to their material properties. The goal is to calibrate and implement all metal materials from EOS in the future.

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Amphyon simulates the AM building process before it actually takes place,

highlighting and optimizing possible problematic areas of the part to be built. Shape accuracy, surface quality, and build productivity and stability can be increased.

With 3D printing service bureaus, a typical process of transforming CAD files into printed part accounts for more than 75% of the total cost. So most bureaus would rather not run multiple test prints to determine the suitability of a part for 3D printing, especially in the case of metal 3D printing and the production of high-value, custom metal components with complex geometries. On average 15% of these metal parts will fail to print properly. To solve this issue, Materialise launched simulation software that is specific to metal 3D printing. In combination with its Materialise Magics 3D Print Suite, the software brings simulation for additive manufacturing to the production floor. Operators can use this program to predict and analyze the behavior of a part by creating a virtual prototype. Then, they can

optimize the build preparation and thereby reduce the number of costly reprints and fails. Users can apply simulation results directly to the support generation and orientation tools in the Magics environment. It supports fast reruns on a standard workstation without the need for high-end processing power, and can also be used in combination with other computer-aided engineering (CAE) programs for certified metal production. The module includes an integrated calibration feature, which guides users to the correct simulation settings for their metal machine. The Materialise simulation module for 3D printing is based on an OEM version of the Simufact Additive Solver. Simufact Additive is a scalable software tool for the simulation of metal-based AM processes.

Siemens announced an Additive Manufacturing Process Simulation solution for predicting distortion during 3D printing. The product is integrated into Siemens’ endto-end Additive Manufacturing platform. Building on the Simcenter portfolio, the AM Process Simulation uses a digital twin to simulate the build process prior to printing, anticipating distortion within the printing process and automatically generating the corrected geometry to compensate for these distortions. The simulation product helps predict possible warp and structural problems in metal 3D printing. The simulation product is integrated into the Powder Bed Fusion Process chain in the Siemens PLM Software Additive Manufacturing portfolio. It provides a guided workflow to the user that assesses distortions,

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Materialise launched simulation software that is specific to metal

3D printing. In combination with its Materialise Magics 3D Print Suite, the software brings simulation for additive manufacturing to the production floor.

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a prediction of recoater collisions, prediction of areas of overheating, and other important feedback about the print process. The AM Process Simulation solution lets users iterate on a solution between the design and build tray setup steps of the workflow and the simulation step. The simulation data creates feeds into the digital thread, which informs each step of the printing process. This digital backbone enables the system to develop pre-compensated models and feeds them seamlessly back into the model design and manufacturing processes without additional data translation. Streamline additive production 3D Systems offers its comprehensive engineering software portfolio for streamlined prototyping and production workflows in both traditional and additive manufacturing. These programs streamline the entire manufacturing workflow from

digitization, to design and simulate, through to manufacture, and inspection. 3DXpert 14 is the company’s newest version of its all-in-one Design for Additive Manufacturing (DfAM) software. The enhancements to 3DXpert 14 focus on facilitating the entire production cycle and will support manufacturers as they move from using additive manufacturing for prototyping to full production applications. The software helps print managers optimize total cost of operation (TCO) through reduced print times, material consumption and post-processing labor requirements. 3DXpert 14’s includes intelligent multi-head control and auto-balancing. Through enhanced control including laser synchronization, gas flow and correct hatching order, the software shortens the print time for large parts while helping maintain material integrity. Built-in templates and automation tools shorten print preparation time from design

to the first batch of repeatable quality prints, including: More options for orientation analysis using stress approximation, New support structure options, New lattice structure options and ready- made templates for generating lattices, Enhanced access to Build Simulation including free versions for education as well as a new standard and professional version.

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Implementing production procedures in dental applications Medical applications are one of the major industries benefiting from additive manufacturing. More software is arriving that automates various stages for manufacturing. For example, QuantAM Dental software, from Renishaw, automates additive build preparation for hundreds of dental frameworks in one operation. The software cuts preparation time from a typical two hours or more to around 30 minutes.

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Dental production facilities typically receive hundreds of custom design files daily from multiple customers. Most of these facilities used multiple programs to handle file preparations for production. “QuantAM Dental consolidates the number of software packages needed to produce batches of frameworks, reducing licensing overheads, decreasing training requirements and reducing build preparation times,” says Ed Littlewood, Marketing Manager at Renishaw’s Medical and Dental Products Division. QuantAM Dental automatically imports hundreds of dental frameworks, repairs the .STL files if necessary, and automates part orientation so that framework cavities face upwards, avoiding supports on the fitting surfaces. It also automatically adds an identification tag to each framework

for reconciliation of designs, and finally, generates supports. The software then groups framework types according to manufacturing requirements. For example, frameworks that require heat treatment, such as bridges, are grouped separately from those that do not. Frameworks not requiring heat treatment are quickly identified before that step in the process is completed. Finally, QuantAM Dental reviews the files and gives a list of potential errors for any sub-optimal frameworks. The systems operator can then slice the build files ready to transfer them to the AM system. And finally, check into SolidWorks and PTC additive features in these companies CAD programs. These two companies have been developing functions for additive for several years DW.

3D Systems | www.3dsystems.com Additive Works | www.additive.works AMFG | www.amfg.ai EOS | www.eos.info Materialise | www.materialise.com Renishaw www.renishaw.com/en/dental-products Siemens PLM Software www.siemens.com/plm/ additivemanufacturing

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| Joi Ito

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Former Google VP and White House CTO Megan Smith believes that greater diversity will make engineering teams stronger — and that data can solve some of our toughest problems.

Technology for all

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When Megan Smith was in public school in inner city Buffalo, N.Y., her teachers created a mandatory science fair. The teachers didn’t want the students to simply go through the motions when choosing a project — instead, they pushed students to choose something that they were really passionate about. The answer was obvious for Smith. The energy crisis was in full swing, and she’d heard that Jimmy Carter was having solar panels installed on the White House.

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I really like working on things that help people with their lives and I like working with things that reduce the impact on the planet. So those have been my general themes, as well as working with adventure and working with great people on things that could matter.

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“I became interested in how we could use green energy to solve this problem that fossil fuels had gotten us into. So, I looked at solar, wind, geothermal, and hydrogen storage,” she said. Smith followed this passion with a trip to Boulder, Colorado, where she participated in a tech project over the summer with a curriculum focused on solar energy and energy engineering. She worked with other kids from around the country and discovered mechanical, civil and other kinds of engineering. That experience convinced her to go to an engineering school. Smith attended MIT, where she majored in mechanical engineering and eventually worked at the institute’s renowned MIT Media Lab. She learned the power of teamwork by getting involved in a solar car project that designed and raced vehicles 2,000 miles across Australia, but soon she changed directions. “I ended up moving from green energy because as Reagan came into power, the Saudis dropped the price of oil — so there really wasn’t funding to move into green energy at scale,” she said. “I ended up moving more towards the internet, which is how I ended up in the Media Lab.” From there, Smith’s career took some interesting turns. She went to Apple Japan and worked on some basic services like Apple link and AOL, as well as early multimedia, CD-ROMS and video. Then she met Bill Atkinson who was one of the co-creators of Macintosh, and he hired her for his startup called General Magic. “We worked to build a smart phone company, way before smart phones existed,” she said. General Magic worked on numerous ideas that were revolutionary for a phone at that point, such as touch screens, LCDs, and connectors. But Smith said that while the company was correct directionally, it had formed too early. But she noted that the people there, sometimes multiple companies later, were the ones who brought us the iPod, iPhone and Android.

January 2019 www.designworldonline.com

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“Most of the phones on the planet come from the heritage of that company,” she said. “I think that’s another important engineering perspective — you have to iterate before you’re successful, you’re always learning with each step.” Smith worked on a lot of hardware as well as a lot of partnerships while at General Magic, so she was interacting with Sony, Motorola, Philips, Apple, as well as with telecom carriers like AT&T. This allowed her to learn the business side of things. She describes her time there as like going to business school, allowing her to apprentice, train, and master different aspects of the job. Ultimately, that company (which is the subject of a brand new documentary film) didn’t succeed, and Smith went to work for Planet Out, founded by her friend Tom Riley, an early leader in queer media. Smith rose to become CEO of the organization and got it to a cash flow positive position before it merged with Gay.com. She then took a bit of time off when her oldest son was born, and then went to Google for 11 years. When she arrived, Google had about 1,200 employees, but it grew to more than 50,000 during her tenure, in which she eventually served as VP of business development. She helped Google acquire companies that became products such as Google Earth, Maps and Spreadsheets — anything that was product-centric. Tech for the people Smith was tapped by President Obama to be his third Chief Technology Officer, a role she held from 2014 to 2017. “President Obama saw a need early on, and asked, ‘Why do I have a surgeon general and a lawyer and an operator and a communicator, but I don’t have a technical person in the core team? I have them, of course, at NASA and NIH and Energy and in the lab, and those are amazing technical people. The government has an IT team that’s supporting everyone and building the systems, but why don’t I have a technical policy capacity builder, just like I have surgeon general or a lawyer?’ And that was a pretty new idea. It still really is, it’s really the beginning of digital, open data driven, collaborative government,” Smith said. “We’ve had tech upgrades before — for example, President Lincoln got the Pony Express, and he had to move us to the telegraph. It’s not like upgrading capabilities is a new idea, but often it leads in certain agencies rather than across them — and I think President Obama could see

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this need for these Americans that he saw in the private sector who were missing. Not missing in government — but missing in the leadership team.” The U.S. CTO role has now been put into law by Congress. It sits together with the President’s Science Advisor in the Office of Science and Technology Policy, Smith said. But it’s also an assistant to the President. The CTO role is to help the President and his/her team harness the power of data innovation and technology on behalf of the American people. The President also has a Science Advisor, generally a scientist or someone with technical/STEM background who’s run labs or done research. According to Smith, the CTO’s more of an entrepreneurial disrupter techie. “The idea is pulling in that entrepreneurial character that we see in Silicon Valley right now — to advance the capabilities of the government and the American people in these areas, and bring that know-how into the policy conversations,” she said. One of the things Smith and her team focused on was open data. They opened more than 200,000 data sets. This isn’t private data, such as from the IRS, but general public data from the U.S. Geological Survey (helpful for mapping apps), weather data and NOAA data sets, HUD, the Census, and so forth. This helped create things like the College Scorecard, where young people who are choosing schools can look at how much each one costs, what’s the graduation rate, what kind of money do people make when they leave. There’s a methodology that comes from Silicon Valley that Smith is very fond of. She calls it Scout and Scale. “The venture capitalists don’t make these companies, they find amazing entrepreneurs and they support them through all kinds of ecosystem methods and practices,” she said. “What if we could do that around solving any kind of problem? Who already figured out what to do? Who has something working or promising, typically regionally, that others don’t know about? How would you scale that?” As an example, Smith’s team created TechHire, a program for adults trying to get into tech jobs. “At the time there were 600,000 jobs open in tech, and companies were starving for employees. We could see St. Louis and other cities were doing these short course boot camps. In a couple months, with intense training, people could become what’s called ‘no collar tech.’ So they’d learn to code and then could apprentice their way into these companies and then suddenly they don’t have to move from San Antonio or St. Louis or Albuquerque or wherever they are.” “What’s interesting now is 23,000 Americans will graduate from boot camps in coding, and at the time it was maybe a thousand or so, but we could see this emerging. We could see in Louisville that the mayor there had done Code Louisville with teens there. In Delaware, the employers’ part of the ecosystem was pleading for people. And so they were jamming community colleges. President Obama was going to Boise, Idaho and we found 15 tech Meetups. But no one in Boise knows that’s happening, so in a way we were taking some of the community organizing principles that you would

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use for a potluck church picnic or something, but as it applied to economic policy and capacity building.” Smith feels that government needs to keep thinking technology and data. “This pattern of looking to tech is emerging massively at commercial enterprises like Walmart. It hadn’t been emerging as much in government except in the deeply technical ones, like a DOE. Think about the Department of Transportation. When Secretary Fox came into that job, there was no conversation in his confirmation hearings about technology at scale. And yet by the time he finished, he had worked on all the rules for UAVs, for self-driving cars, for next gen air traffic. His had become a technical agency. Before that, it was much more civil engineering, mechanical engineering, energy engineering — now, it’s that plus digital. Into the engineering fold Smith has long been passionate about bringing more diversity into the engineering and tech

worlds, from women to people of color to the LGBTQ community. And she has some specific advice for young women or other minorities considering a career in engineering. “Engineering’s a fabulous background, just like liberal arts,” she said. “And you want to take lots of different classes. If you’re in the liberal arts, take an engineering class, take a data science class, take some other things. If you’re in the engineering side take some liberal arts classes. And social science classes and other things,” she said. “You can have a huge impact on the world. It’s creative job, it’s a teamwork job. You can be on amazing teams and do this work. There is a lot of discrimination because there’s a lot of stereotypes. There’s history that’s missing so you don’t really learn that everybody’s been awesome the whole time.” Smith said that there is a lot of culture that can be debilitating to certain people. “Stand on the side of the pool when

astronauts are about to do some kind of underwater testing. When a guy steps up, people say, ‘Wonder what he’s going to do today?’ When a woman or man of color steps up there’s more of a, ‘Hmm, wonder if he can do it?’ You’re fighting internalized and externalized stereotyping constantly.” “It’s so interesting, because the true history of astronauts is that a lot of people thought women should be the first astronauts because they were smaller. And there was the Lovelace Project that showed that they actually performed equally or better on certain tests. But it was, I think Johnson, who said, ‘No, we’re going to do test pilots.’ And since test pilots were discriminatory, then only men could do it. That’s what happened to us. As opposed to the Soviets, who had a man and a woman right away.” “We have a lot of work to do to pull out of that, and I think that one of the key things that you can do is know that you’re

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not alone in the challenges that are there and find community. Find women and men who are supportive of you. And work with them.” “You know, there are companies in Silicon Valley where some of the diversity folks there will forewarn people, ‘Don’t come to this company because it isn’t awake yet. And it’s discriminatory.’ A lot of the Silicon Valley companies have a culture of intellectual combat in how they interact with each other. It’s just unnecessary to behave this way. But because of that, young people being mentored in that can write goofy memos like that kid from Google. [A young male software engineer was fired in 2017 after writing a memo in that relied on gender stereotypes] That’s what he saw, and he didn’t know the context, and so he just wrote this superficial perspective. Even though it’s a culture that’s creating that problem, not anything based on science.” Smith said that the only companies and organizations that make progress are ones that

realize diversity should be shortlisted in terms of priorities. For many companies, it’s a shareholder value and they put it in their top 20. But that’s just too low, she insisted. “It needs to be in the top three,” she said. “We saw companies like Intel and Slack and others who moved it to the shortlist, and all of a sudden started to make great progress. Lou Gerstner, when he was turning IBM around, said to his management team, ‘We’re not a diverse team, but we don’t have to be ignorant. And so I want all of you to spend time with these employee research groups and we’re going to add it to the agenda. And every week this will be something we touch on.” Communication as a skill for engineers Smith, who is now the CEO of shift7, a recent startup in the tech collaboration space, said she feels that it’s really

important for engineers to work on their communication skills, just like everybody else. “Anybody who is a good communicator has usually worked on those skills, and practiced speeches and gotten feedback, learned to write. You know, make an argument, put yourself out there. It’s really important in any profession, engineering or otherwise, you have to be able to sell your idea,” she said. “One of the people who I got to work with, Eric Schmidt (former Google chairman), did a huge amount of work around learning, speaking, and communicating, and bothered to pay attention to that, just like you would be current on the latest technology. I think it’s an important thing for engineers. We also have to shift the culture to support people in communicating better. If you’re not as strong at communicating, get a teammate. Work together.” DW

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LEAP Awards’ first year proving to be a huge success

Paul J. Heney | VP, Editorial Director

When we launched the LEAP Awards this past Spring, I wasn’t sure what to expect. Looking at similar “best product” type competitions across multiple industries, it seemed reasonable to expect a few dozen entries in this inaugural awards program. So, I was very pleased when we received more than 100 entries! The categories for LEAP are roughly divided across three of our flagship publications’ brands: Design World, Fluid Power World and EE World. These eleven categories represent products and components across the engineering spectrum. • Additive Manufacturing • Advanced Materials • Connectivity • Embedded Computing • Fluid Power • Industrial Automation

• Mechanical • Motion Control • Power Electronics • Switches & Sensors, and • Test & Measurement.

Our company’s publications have acted as important information sources for readers over the past dozen years. We’ve presented new products across the mechanical and electrical engineering space, talking about their launches, looking at the applications where they’re being used, and investigating how they fit into the bigger system design picture. LEAP now gives us a new

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avenue in which to bring you additional, unique product information — what’s truly innovative as well as what stands out among an always-crowded field. Critical to LEAP’s success is the involvement of the engineering community. No one here at WTWH selected the finalists and winners. Instead, our editorial team did the arduous work of assembling a top-notch independent judging panel, comprised of a crosssection of OEM design engineers and academics—18 professionals in total. This judging team was solely responsible for the final results. For this year’s awards competition, products had to have been released within the past two years and be available for commercial purchase in the United States. Finalists and winners in each of the 11 categories are listed on the following pages. The winners were announced at a gala awards banquet in conjunction with DeviceTalks West in Costa Mesa, California last month.

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I’m pleased to introduce you to our esteemed judging panel.

Bonnie Baker Consultant ATW, LLC Bonnie Baker is the author of six books, including A Baker’s Dozen: Real Analog Solutions for Digital Designers. Baker holds a Master’s of Science in Electrical Engineering from the University of Arizona and has authored more than 500 technical publications including magazine articles, app notes, seminar sessions, data sheets, and a few patents. She is also frequent presenter at technical conferences and shows. She has been involved with analog and digital systems for more than 30 years. Baker started as a manufacturing product engineer, supporting analog products at Burr-Brown. From there, she moved up to IC design, analog division strategic marketer, and then corporate applications engineering manager. In 1998, she joined Microchip Technology. This expanded her background to not only include analog applications, but microcontroller solutions as well.

Carl Dekker President MET-L-FLO Inc. Carl Dekker is President of Met-L-Flo Inc., a Contract Manufacturer specializing in 3D Printing and Additive Manufacturing. The company has been providing these services since 1991 and usees multiple different technologies for its clients. Dekker has presented his work at various conferences globally and has been published in various industry journals. He is currently the Chair of the ASTM F42 Committee on Standards for Additive Manufacturing, VP of the Additive Manufacturing Users Group, and a Past Chairperson of the SME’s Rapid Technologies and Additive Manufacturing (RTAM) Community (formerly the RPA). He is also a proud recipient of the SLA “Dinosaur” award. Past and present positions held include: Rapid Prototyping and Manufacturing Conference Advisor (2002-2018), Industry Advisory Board Member for RapidTech (2010-2014), RapidTech National Visiting Committee Chair (2011-2014), T.E.A.M. NAB (Technician Education in Additive Manufacturing National Advisory Board) Member 2011-2014, 2017, Museum of Science and

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Industry Fab-Lab Advisory Board Chicago (20092012), Waubonsee Community College Industry Advisory Board (2008-10), Valley Industrial Association Board Member (2009-12), National Design and Manufacturing Conference Advisor 2005, National Plastics Exposition Conference Advisor 2006 and 2009 and Secretary of the 3D Systems North American Stereolithography Users Group 2003 and 2004. He has also served as the Chair of many specialty programs and conference sessions.

Plamen Doynov Research Professor University of Missouri-Kansas City Plamen Doynov became a research professor in physics last year, after a long and storied career that included stints as the Principal Engineer at MRIGlobal, a Biomedical Engineer at Flint Hill Scientific, and VP of Electrical Engineering at Aviation Simulation. He holds a PhD in Electrical Engineering and Computer Sciences from the University of Missouri-Kansas City and a Master’s in Electrical Engineering from The Catholic University of America. Doynov has been active in and a local board member of the IEEE and has won numerous honors and awards from the MRIGlobal Council of Principal Sciences, Boeing and the Bulgarian Society for Biochemistry and Biophysics. He has experience in electronics, electrical and biomedical engineering, as well as research and development of specialized scientific systems.

Bradford L. Goldense President Goldense Group Inc. Bradford L. Goldense is a subject matter expert in the management and processes of product development, innovation and performance measurement. He has authored or been cited in more than 300 articles and books and holds nearly 150 registered copyrights. Brad was a faculty member of the Graduate Engineering School Executive Program at The Gordon Institute of Tufts University for 19 years. He is internationally recognized and has DESIGN WORLD

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DRIVING YOUR INDUSTRY 4WARD.

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consulted with more than 200 of the Fortune 1000 in 500 manufacturing locations around the world. GGI has helped many companies to increase their stock price by improving R&D innovation and execution, and by improving communications of prowess to the marketplace and investor community. He previously held positions at Texas Instruments, Price Waterhouse, Knight & Associates, Index Group, and a family engineering business before founding GGI. Brad has a BSCE from Brown University and an MBA from Cornell’s Johnson School. He holds four professional certifications: New Product Development Professional by the Product Development and Management Association, Certified Manufacturing Engineer by the Society of Manufacturing Engineers, Certified Computer Professional by the Institute for Certification of Computer Professionals and Certified in Production and Inventory Management by the American Production and Inventory Control Society. Brad was a founding member of the Society of Concurrent Engineering and founder of the Society of Concurrent Product Development which he ran until 2006. He retired from the board in 2012. His non-profit corporation lives on, with appreciated support and funding from 3M.

Geoffrey T. Haigh Principal/Senior Partner Haigh Consulting LLP Geoffrey Haigh holds a BS in Physics and Instrumentation from Drew University and is a Principal Partner and Senior Scientist form Haigh Consulting, which creates IP and solves problems for clients. Haigh has 31 patents issues worldwide and was the originator and inventor of the ADI ICoupler technology during his time working for Analog Devices Inc. Devices he has designed and patented are on Mars rovers. He also previously worked for Analogic Corporation on factory automation systems and nuclear measurement instrumentation.

Russ Hempstead Senior Development Engineer Just Right Surgical Russ Hempstead has been working in the medical device industry for more than 25 years. He has focused on early stage design and development through manufacturing

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of class II medical devices. Biomedical engineering was an obscure specialty when he attended college, so he pursued his degree in mechanical engineering with an emphasis in polymer science. Hempstead has extensive experience in clinical settings for the purposes of early concept generation, as well as product launch. Clinical settings include animal and cadaver labs for product validation activities and hospital operating rooms for procedure familiarization and observation. He has led engineering teams in various facets of device development and manufacturing for the last 13 years. In all of those instances, he was an individual contributor in addition to the project manager. Hempstead has been considered a subject matter expert in the areas of plastic material selection for biocompatibility and sterilization, design for injection molding, design for manufacturability, and finite element analysis.

Sam John President Innovative Products Inc. As President of Innovative Products, Sam John is responsible for the design and manufacturing of various custom-built automatic machines for different industries. He also resolves design and manufacturing issues, conducts project meetings and issue status reports, manages budgets, submits project proposals, and directs projects. He’s worked with clients as varied as Medtronic, Tinker Air Force Base, GE Oil and Gas, and AVARA Pharmaceutical Services. Previously, he worked for Sorb Technology (now Fresenius) and Akzo-Nobel. A member of the ASME, John has an MBA from Oklahoma City University, a Master’s in Mechanical Engineering from the University of Oklahoma and a BS in Mechanical Engineering from the University of Calicut.

Dan Jones President Incremotion Associates Dan Jones started as a production worker at a motor company in the late 1950s, balancing ac squirrel cage rotors and pressing shafts into rotors. He earned his BSEE from Hofstra University in 1965 and a Master’s in Math from Adelphi University in 1969. He has more than 50 years’ experience as a motor design engineer, manager, chief engineer, marketing director, vice president of marketing,

January 2019 www.designworldonline.com

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and consultant. Jones is experienced in custom motion marketing activities, surveys and strategic planning meetings and is a Life member of IEEE. He employs SPEED and MotorCAD for the design of all types of linear, radial, flux, and axial flux machines, PM brushless, switched reluctance and induction machines. Jones is the author of more than 250 seminars, papers and technical articles on a wide range of motion control subjects. He was project manager for the design and development of six specialty DC motors used on the two Mars Viking Landers in 1976.

Robert Kollman Director Kollman Power Engineering Robert Kollman is a power electronics designer and researcher with more than 45 years of experience, mostly with Texas Instruments. There, he led the development of high-volume power supplies for commercial production at TI’s strategic customers. Kollman’s Group developed more than 5,000 power supply designs — ranging from mW to kW of output power. Kollman is a prolific author, with more than 150 published contributed articles including the well liked “Power Tips” series. He was heavily involved in the Unitrode Power Supply Design Seminars including writing articles and making presentations.

Thomas E. Manley Engineering Manager Feedall Automation Thomas Manley is Manager of Engineering at Feedall Automation, where he directs and designs the machine orders that come through the engineering department. He is also a part-time engineering instructor at Lakeland Community College and is the designer of 14 U.S. Patents for various companies that he has worked for. Manley has worked with high-profile companies such as Harley-Davidson, American Axle, Meritor, Caterpillar, and Ford Motor Company, among others. He helps companies and engineers implement automation systems into their plant, while adhering to their desired budget and goals.

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Kristin Morris Lead Electrical Engineer Pacific Diabetes Technologies Kristin Morris is the Lead Electrical Engineer at Pacific Diabetes Technologies, a Portlandbased startup developing an integrated solution for glucose sensing and insulin delivery. She is involved in every level of design, from the lowlevel PCB and firmware, to mobile applications and data processing. Morris holds a Master’s of Engineering Degree in Computer Engineering from Portland State University. During her studies, she also received valuable work experience via internships at large corporate companies such as Intel, Mentor Graphics and Electro Scientific Industries (ESI). She then kicked her career off by continuing on at ESI full time, before making the leap into the startup world in 2013, where challenges, inspiration, failures and successes awaited.

Russell Olmsted Project Engineer Arrow Tech Company Russell Olmsted is a Mechanical Engineer with experience in product development, product management, and distribution sales. He also has expertise in compressible and in-compressible fluid applications, fluid power applications and components focused on filtration, pump, and motors, and specialty and compressed gas components. Olmsted is currently a Project Engineer at Arrow Tech Co., where he reviews and evaluates current work-flow processes with Arrow Tech and M&D Welding daily. His expertise involves developing contact-record-management (CRM) capabilities, providing technical support to marketing and operations to resolve any issues with existing products, and developing solutions to production problems related to materials, processes and tooling.

January 2019 www.designworldonline.com

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Ernie Parker Retired Professor Hennepin Technical College Ernie Parker started his education at Granite Falls AVTI (now Minnesota West Technical College) and went to work at the Char-Lynn Company after graduating. He then joined the Army, where he was trained as a Radar Technician and served in Vietnam. In 1971 he returned to Char-Lynn (now Eaton Corp.). He worked in various capacities as an Engineer, Assistant Purchasing Agent, Draftsman, Electronic Tech, and Hydraulic Tech. While at Eaton after the service, he attended evening school and obtained his teaching licenses. He eventually began teaching in the Fluid Power Technology area at Hennepin Technical College and became the manufacturing Department Chair in 1995. In 1977, he started Hydra Tech Inc., a consulting and fabrication company for hydraulics and pneumatics. Parker has built more than 200 test benches, training benches, and all kinds of different equipment for companies like Boeing, Donaldson Co., 3M, John Deere, Caterpillar, Eaton and many others. He is on both the Education Board and the Certification Board of the IFPS. Parker also works with the NFPA (National Fluid Power Association) with their bicycle vehicle challenge for university capstone projects. Hennepin Technical College Foundation receives his help as a Board of Directors member to support scholarships for students. He feels very honored that he has been able to help individuals find their direction in life and educated over 1000 students and industry personal over his career. In 2009 he received the” Educator of the Year” award from the Board of Trustee for the State of Minnesota that includes 37 two-year and four-year colleges, 54 campuses and more than 11,000 full and part time faculty.

Karl H. Schultz President Schultz Associates Karl Schultz is the President of Schultz Associates, specializing in manufacturing and technical management consulting in the electric motor industry. He is also considered an expert in implementing lean/world class

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business processes. Schultz is an experienced hands-on manufacturing management consultant who has had both line and staff positions in the electric motor industry. He was the division Director of Manufacturing Engineering for Emerson Electric for 10 years, supporting four plants in the U.S. and Mexico. He was then the Business Director of Manufacturing Engineering at GE Motors for three years. Consulting has taken him worldwide in many various successful projects. He has more than 25 years in the electric motor industry. Schultz holds a BSME in Machine Design from Western Michigan University. He was a member of the Electrical Manufacturing and Coil Winding Association, serving as the VP and a Board member. He is a senior member of the Society of Manufacturing Engineers and a past member of the Society of Automotive Engineers. He has received numerous awards such as Best Industry award (General Signal), Most Valuable Player award (BMI), performance awards (GE Corporate & Motors), and others. He is an adjunct instructor at the Oregon Institute of Technology – Wilsonville, teaching junior and senior level management courses such as Lean/6 Sigma and Organizational Behavior.

Bill Schweber Engineer, Author, Editor Jaffa Engineering Bill Schweber is an electronics engineer who has written three textbooks on electronic communications systems, as well as hundreds of technical articles, opinion columns, and product features. At Analog Devices Inc., he was in marketing communications, so he has been on both sides of the technical PR function, presenting company products, stories, and messages to the media and also as the recipient of these. Prior to Analog, Schweber was associate editor of the company’s respected technical journal, and also worked in their product marketing and applications engineering groups. Before those roles, he was at Instron Corp., doing hands-on analog- and power-circuit design and systems integration for materials-testing machine controls. He has an MSEE from the University of Massachusetts and a BSEE from Columbia University. He is a Registered Professional Engineer and holds an Advanced Class amateur radio license. Bill has also planned, written, and presented on-line courses on a variety of engineering topics, including MOSFET basics, ADC selection, and driving LEDs.

January 2019 www.designworldonline.com

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Tom Solon Director of Sales and Marketing RH Murphy Co. Inc. Tom Solon has a diverse engineering background in roles as both an OEM and supplier, spanning many industries, from housewares and consumer products, to semiconductor manufacturing and medical equipment technology. A recognized authority in linear motion products, plastics, and semiconductor handling, Tom has authored numerous articles and technical papers. Tom earned his BSME in Machine Design and BA in Economics from Brown University and is a licensed Professional Engineer. He devotes much of his free time to public education as a school board member and technical education advisory board member.

Michael Torres Chief Avionics Support Equipment Engineer Naval Air Warfare Center, Weapons Div. Point Mugu

Mike Vasquez CEO 3Degrees, LLC Dr. Mike Vasquez is a 3D Printing expert, specializing in pushing the boundaries of advanced 3D printing technology. He is the Founder of 3Degrees, a Chicago-based consulting company focused on helping organizations maximize their investment in the technology. Over the past decade, Vasquez has worked sideby-side with some of the top machine manufacturers, material producers and end users in the industry, consulting with them to identify novel applications, test new materials, and develop frameworks to maximize R&D efficiency and boost ROI. He has also created a software tool called Trace. It aims to assist companies formalizing their use of 3D Printing to ensure they can meet quality and technical standards outlined by their supply chain and industry requirements. Vasquez completed his PhD in Additive Manufacturing at Loughborough University and received both his Bachelor’s and Master’s from MIT in Materials Science and Engineering.

Michael Torres’ technical expertise is the design, development, and testing of advanced avionics (flyable electronics) that meet speed, size, weight, and power requirements of these systems. He focuses on the development of software mathematical algorithms to facilitate design solutions that meet these requirements. Torres has developed and patented automated test systems for avionic systems and their test equipment. He holds nine Navy patents and is an expert in the development of manufacturing fixtures that simply the manufacturing of components, reducing the manpower requirements and producing better and more repeatable results. Torres holds a Master’s of Science in Electrical Engineering specializing in Electronic Warfare from the Naval Post Graduate School, a Master’s of Science in Electrical and Computer Engineering from University of California at Santa Barbara, and a Bachelor of Science in Electrical Engineering from UCLA.

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247 Lynnfield Street, Peabody, MA 01960 • 978.532.1800 • www.HarmonicDrive.net Harmonic Drive is a registered trademark of Harmonic Drive LLC. Valkyrie image courtesy of NASA.

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Winners + Finalists Folliowing are the winners and finalists, in alphabetical order, for the 2018 LEAP Awards:

• Additive manufacturing

• Embedded computing

Winner:

Winner:

Littelfuse MP8000 Bluetooth Enabled Motor Protection Relay

HP Inc. Jet Fusion 300/500 Series

Microchip Technology Inc. SAM L11

Omron Automation Americas CIP Safety Controller

Other finalists:

Other finalists:

Parker Hannifin Universal Pneumatic Valve Manifold

3D Systems Figure 4

Mentor, A Siemens Business Mentor Embedded IoT Framework (MEIF)

• Advanced materials

RelChip, Inc. Extreme Operating Microelectronics (EOM)

Winner: L.J. Star Incorporatedc MetaPlex Optical Grade Polymer Sanitary Sight Windows

• Fluid power

Protolabs Farmbot - humanity’s first opensource CNC farming machine Schneider Electric EcoStruxure Augmented Operator Advisor Serapid Telescopic Jib

Winner: Other finalists: Dura-Bard Solution Strengthened Ductile Iron

Eaton Corp. Boom Stability Control System

• Mechanical Winner:

Other finalists:

• Connectivity

Danfoss Power Solutions D1 Pump

Winner: Fischer Connectors Fischer Freedom LP360 Other finalists: Cicoil Micro IDC Cable I-PEX Connectors MHF I LK Micro RF Coaxial Connector Silicon Labs Wireless Gecko SoC

Rolling Motion Industries Traction Drive Technology Other finalists:

FD-Groups America, Inc. Auto-Steering Valve Festo Evolutionary Intelligent Pneumatics

• Industrial automation Winner: Omnify Software Omnify Empower / 6 River’s Robot Chuck

CPC - Colder Products Company Ultra-Compact LQ2 Quick Disconnects R+W Coupling Technology World’s Largest Ball-Detent Safety Coupling Twin Spring Coupling TSC500 flexible coupling unit WITTENSTEIN Rack Assembly in Minutes, Chipless Pinning with INIRA

Other finalists: Cognex DataMan 470

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Discrete Semiconductor Solutions for

Extreme Environments

Winners + Finalists • Motion control

• Switches & sensors

Winner:

Winner:

maxon precision motors Exoskeleton Joint Actuator

Omron Automation Americas A2W Wireless Pushbutton

Other finalists:

Other finalists:

AMETEK Windjammer Pro Brushless Blowers

RAFI RAMO Series Industrial Controls

ElectroCraft RPX and LRPX

Renesas Electronics CMOS Image Sensor

GAM Enterprises Zero backlash gearbox

• Test & measurement Winners (tie in this category):

Haydon Kerk Motion Solutions, Inc. 15mm Linear Actuator

Super Industrial : TM

Upgraded versions of standard commercial and industrial discrete semiconductor products.

spacellite : TM

Enhanced devices designed to meet the reliability and functionality specifications for today’s satellite applications.

Anritsu Signal Quality Analyzer-R MP1900A BERT

Kinitics Automation KLA05 Linear Actuator

and

Lin Engineering Miniature Hybrid Step Motor

Keithley Instruments DMM and DAQ

Oriental Motor USA Corp. Battery-Free Multi-Rotation Absolute Mechanical Encoder

Other finalists:

• Power electronics Winner:

Mentor Graphics T3Ster and FloTHERM and FloTHERM XT Calibration Tektronix 6 Series MSO Mixed Signal Oscilloscope

Maxim Integrated Himalaya uSLIC Solution Other finalists: CUI Inc. High Performance Peltier Modules with arcTEC Structure Mentor Graphics MicReD Power Tester

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Power Integrations InnoSwitch 3-Pro

145 Adams Ave • Hauppauge, NY • 11788 • USA

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w w w. c e n t r a l s e m i . c o m

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DESIGN WORLD

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SOONER OR LATER, CUSTOM IS CRITICAL! And when it is, your best partner for custom motion products is Allied Motion. From simple cable and mounting modifications to cleansheet motion systems, Allied Motion is the industry leader in customized motion soutions for virtually any application. Don’t force fit standard motion products into your designs. Call Allied Motion when custom becomes critical.

CW from upper left: security door latch bolt; GPS-guided vehicle steering actuator; dual BLDC mil-spec actuator; armored vehicle door actuator

Motion Solutions That Change the Game www.alliedmotion.com • inquiry@alliedmotion.com

Americas: 1(716) 242-7535 Critical Customs 1p4c (Design World).indd 1 Allied Motion 1-19_DW.indd 189

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Product World Custom coupling for extra parallel misalignment Zero-Max zero-max.com Drawing from experience, Zero-Max engineers have customized a shortened version of the Model 6P60C CD coupling. Designed with a composite disc center member, this coupling handles misalignment, minimizing reaction loads in a confined operating space much better than the previously used steel disc coupling.

Providing a peak torque value of 12,700 in.-lb, the CD Coupling is torsionally stiff and able to operate

at speeds up to 4,400 rpm. The custom CD Coupling ensures low reaction loads on the system’s shaft bearings. This custom CD Coupling provides up to 3° angular misalignment with 0.069 (1.8 mm) parallel and 0.260 (6.6 mm) axial misalignment also allowed. Also, the coupling has aluminum hubs that have little inertia.

The modified couplings provide a straight forward solution. They are easy to install by simply removing

the failed coupling and connecting the newly modified CD Coupling’s clamp- style hubs in the system’s power train, without having to redesign or relocate any machine components.

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Hydraulic components for usage in extreme environments

High Pressure Components

HAWE seated valves provide directional control with zero leakage

Additional functions for intelligent solutions:

Solenoid actuated valves with integrated additional functions for clever controls in compact design

Compact Combinations

Valve combinations used for lifting equipment with one or two single acting cylinders

Industry Leading Performance

Proportional directional spool valve PSL

HAWE hydraulik is aware of the importance of functioning explosion protection in extreme environments and provides products that are in accordance with global standards. We manufacture the highest quality hydraulic components to maximize space and product durability for the mobile, industrial and oilfield markets.

Partner with HAWE to always have the right solution! We are Partners.

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1/8/2019 10:28:27 AM 1/18/19 9:38 AM


Product World Variable output alignment laser systems BEA Lasers bealasers.com This Alignment Laser System has a variable laser light output suitable for short distances. The dimming feature provides greater flexibility when aligning objects against different backgrounds, such as dark, light, chrome or other shiny surfaces. The new Alignment Laser Systems are also suitable for variable work conditions where lighting and/or the alignment surfaces change or are uncertain.

fitted with a M12 connector, PVC-jacketed

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cable 2 meters long, and a power supply. A choice of mounting hardware is provided: either a sensor style bracket or multiadjustable “LB” bracket. Lasers are available in

For over 70 years, Components Corporation’s PCB Interconnect Products have ensured the highest standards of performance in the most demanding wireform interconnect and testing challenges. • PCB test points

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D


For further information about products on these pages visit the Design World website @ www.designworldonline.com

Micro brakes for small precision equipment applications Ballscrews & Rollerscrews

Miki Pulley mikipulley-us.com 112 Model Electromagnetic Micro-Brakes are a compact, high

Industrial Robots

performance braking solution for small, precise motion control applications. The brake design ensures fast response in high torque demanding applications. The simple design has a stator

Linear Motors

with integrated mounting flange, proprietary composite friction liner, and armature complete with ring plate spring and hub.

Linear Actuators

Field proven, these Micro Brakes halt

rotation mechanically by using the electromagnetic field to create mechanical friction. With fast response, the brake’s armature engages the stator when the coil is energized. A constant-force plate spring

Linear Guideways

transfers torque to the rotating brake body halting all motion.

Additional features include: quiet

operation, high holding torque for its size, space saving design configuration, long service

Linear Encoders / Positioning Measurement Systems

life, stable and reliable braking power. Easily installed, these Micro Brakes require no maintenance. They are available in three armature assembly options depending on application requirements. AC Servo Motors

Specification range based on model selected: • Brake torque: 0.295 – 1.770 ft lb (0.4 -2.4 Nm) • Backlash: Zero • Ambient Temperature: 14 F ~ 104 F; (-10 ° ~ 40 °)

Hiwin D1 and D2 Servo Drives

For more information visit

www.hiwin.com

DESIGN WORLD

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January 2019

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ROSS CONTROLS A Global Leader in Fluid Power Safety

Pneumatic and Hydraulic Safety Solutions

Safe Cylinder Control and Stop

Cat. 4 PLe

Hydraulic Block & Bleed

Safety Exhaust Safe Cylinder Return

Hydraulic Block & Hold

www.rosscontrols.com

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Product World AI controller extends equipment life with machine learning Omron Automation omron.247.com WE Series Linear Guideway Wide Series Ball Type.

The Sysmac AI Controller handles several key steps in the data-driven decision process for predictive maintenance, thereby freeing up industrial professionals from tedious calculations, analyses and infrastructure upgrades.

The AI functionality – also known as “machine learning” – is able to identify abnormal

machine behavior without being explicitly programmed to do so. Since there could be different factors and measurements that indicate an issue when observed together, automating the feature extraction process saves time and resources. Leveraging the machine learning results during production is key to ensuring end user cost savings.

Rather than being a cloud solution, Omron’s approach to artificial intelligence-based

control involves hardware, offline software and in-person service. No internet connectivity or IT infrastructure/service is required. The hardware is based on the Sysmac NY5 IPC and the NX7 CPU and includes Omron’s AI Application Components, a

PG Series Linear Guideway Integrated Magnetic Encoder.

library of AI predictive maintenance function blocks. Several additional AI specific utilities are also included.

MGN / MGW Series Linear Guideway Stainless Steel Miniature Linear Guideway Size 5 Now Available.

HG / EG / RG Series Linear Guideways Ball and Roller Type.

DESIGN WORLD

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Ball Valves

Solutions Under Pressure Power Unit Layout Components

Check Valves

Pressure Gauges and Isolators

Flow Controls

Bar Manifolds

Flanges and Bolt Kits

Adapter Flanges

Quality Components for Hydraulic Power and Fluid Handling Systems Ball Valves • Check Valves • Flow Controls • Power Unit Layout Components Flanges • Pressure Gauges • Manifolds • Cylinders 1-800-248-DMIC (3642) DMIC 1-19.indd 196

www.DMIC.com

Sales@DMIC.com 1/18/19 9:40 AM


Product World Lighting system for machine vision B&R br-automation.com

LM Linear Actuator / SAR Linear motor driven high acceleration and accuracy, unlimited travel.

This integrated vision system features flexible light bars and backlights for optimum results even in difficult lighting situations. Lighting control is synchronized with the automation system in the sub-µs range. As integral parts of the automation system, both cameras and lighting are easy to synchronize with other sensors, motor positions and events in the machine application. Lighting control with microsecond precision is

KA Type Linear Actuator / SAR Ballscrew or belt driven, exible design.

guaranteed when synchronizing multiple cameras and light sources. Broad spectrum of possibilities The flexible light bars are available individually or arranged as ring lights in groups of four, six or eight. The backlights are available in two sizes. Each light can have up to four different LED colors at a time. The selection ranges from white and various visible colors to infrared and ultraviolet. This makes it possible to achieve the right contrast, color,

KK Type Linear Actuator / SAR Ballscrew driven, high accuracy and reliability.

illumination and intensity for any application.

B&R’s light bars feature electronic angle adjustment from -40° to 90°. When

producing multiple products on the same machine, the lighting angle can be optimized between batches – once it has been set, it can be saved as part of the batch recipe.

KS Type Linear Actuator / SAR Ballscrew driven for clean room applications.

AC Servo Motors.

Hiwin D1 and D2 Servo Drives for Servo Motors, Torque Motors and Linear Stages.

DESIGN WORLD

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Product World 3-phase SSRs for panel mounting Carlo Gavazzi Gavazzionline.com The RGC3.‌48 Series, is a 48 AAC per phase rated device with a panel mount or thru-wall mount, natural convection heatsink. To keep the dimensions compact, the existing RGC3 solutions at higher current ratings (above 40 AAC) use forced ventilation and hence require a supply voltage. The new 48 AAC rated 3-phase relay uses a larger, natural convection heat sink that eliminates the need for additional supply voltage if system monitoring is not required.

The device can be panel-mounted inside of an electrical enclosure, or if a side-wall cutout is available, the heatsink portion of the

relay can be mounted outside of the cabinet. Thru-wall mounting offers an additional benefit of keeping the heat generated during the operation of the SSRs outside of the enclosure, away from other sensitive electronic equipment. The 48 AAC rated RGC3‌.48 Series are available with line voltage ratings up to 600 Vac, either dc or ac control, with optional system monitoring featuring electromechanical relay alarm and auxiliary output. Applications include HVAC, Heat Tracing, Plastics or Packaging, especially in situations where supply voltage is not available, or heat generated by the operation of an SSR has to be kept outside of the enclosure.

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YOU DECIDE WHAT’S

Product World One component glob top epoxy

!

Master Bond masterbond.com

Create your own vision solution with our vision app-based camera platform.

The EP17HTND-CCM is a new single component epoxy that is not premixed and frozen. It is more convenient to handle, apply, and store than typical two component glob top systems. This black, heat curable compound has a flowable paste consistency suitable for glob top, chip coating, and bonding applications. EP17HTND-CCM meets NASA low outgassing specifications and is serviceable from -80° to +600°F [-62°C to +316°C]. This adhesive forms high strength bonds to a variety of similar/dissimilar substrates such as metals, ceramics, plastics, composites and various circuit board materials.

EP17HTND-CCM is thermally conductive and

electrically non-conductive even upon exposure to hostile environmental conditions. EP17HTND-CCM has a highvolume resistivity of more than 1015 ohm-cm at 75°F and over 1012 ohm-cm at 400°F. Its thermal conductivity is 9-10 BTU•in/ft2•hr•°F [1.4423 W/(m•K)] at 75°F. Also noteworthy is its ability to resist many chemicals including acids, bases, salts, fuels, oils and many solvents.

®

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Spring Applied Brakes

For further information about products on these pages visit the Design World website @ www.designworldonline.com

Extended range of shaft collars JW Winco jwwinco.com

From the world’s largest manufacturer of world-class electromagnetic clutches and brakes

The Semi-Split Shaft Collars GN 7062.1 with Extension Tapped Holes,

For holding and stopping applications A wide array of standard torque ranges (1.75in/lbs - 880 in/lbs) Custom designed and manufactured for your application Manual release, zero backlash, and adjustable torque also available Inch and metric bores available

GN 7062.2 with Flange Holes, and GN 7062.3 with Damping Washer, along with Two-Piece Shaft Collars GN 7072.1 with Extension Tapped Holes, GN 7072.2 with Flange Holes, and GN 7072.3 with Damping Washer are new from JW Winco.

Electromagnetic clutches & brakes for virtually every application

Available in full, slotted, and split versions, this range of shaft collars

can be used in multiple ways in machine and fixture fabrication. They secure shafts and axles, acting as a positive stop or as an attachment option for additional functional elements. The affixed damping washer

100 Randolph Road • Somerset, NJ 08873 Phone: 732-271-7361 • Fax: 732-271-7580 Website: http:ogura-clutch.com/spring Email: info@ogura-clutch.com

of both versions absorbs mild shocks and has a sound-dampening effect when the shaft collars come

Brushless Motors

into contact with other components.

The shaft

collars are made of sintered steel, while the socket cap screw is stainless steel and the damping washer on both GN 7062.3 and 7072.3 is elastomer, transparent and temperature resistant up to 176 °F (80 °C). There are also standard part accessories, such as GN

• Hollow or solid shaft high performance housed and frameless

7062.30 Elastomer Damping Washers, for Semi-Split Shaft Collars and GN 7062.10 Stainless Steel Sensor Brackets

for Shaft Collars.

• • • •

brushless motors and matching drives for demanding applications. Sensorless or hall motors and drives for aerospace, military, medical, industrial, canned pumps, vacuum, extreme temperature applications. Custom drive programing and designs available. Standard or custom designs up to 98% efficient, up to 200,000 rpm. Highest power density in the industry. Slotless and slotted designs. Available with encoders and gearheads and separate or integral electronics. Quantities 1 to 10,000.

For technical assistance, mail@koford.com 937-695-1275

DESIGN WORLD

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Product World 7-Lamp LED string light Larson Electronics larsonelectronics.com This Class I, Division 2-rated Cree LED string light has seven LED fixtures that operate on 120/240 Vac. This hazardous location unit comes with 13-ft of 12/3 SOOW line-in cord connecting each lamp fixture. This unit is designed for use in areas that are wet, damp or dusty.

The HAL-SL-7-48IPS-LED-13X-1227-JB6 durable LED string light features seven Cree LEDs providing over 83.3 lumens per

watt for a total of 2,443 lumens of light produced. These LEDs have a 70% lumen retention rate and a 50,000-hour lifespan, providing maximum efficiency and life. These lamps produce a color temperature of 5000K and color rendering index of 75. This hazardous location string light operates on 120/240 Vac and includes a junction box allowing operators to make daisy chain connections.

This LED string light is constructed of extruded aluminum with a durable powder coated finish and is weatherproof making it

suitable for indoor and outdoor use. This unit features IP65-rated housings that provide protection against dust and low-pressure water jets from all directions like wash-down areas. Two standard adjustable end brackets are provided for mounting the fixture to flat surfaces with the ability to adjust the lights to a 170˚ angle for best placement where space is limited.

cycloidal reduction gears

Did you mean: DieQua Corporation?

The search is over! The Spinea high precision cycloidal reducers provide unmatched performance, durability, and design flexibility. Look no further than DieQua. • 1 size - TS50 at 50mm • Torque capacity up to 18 Nm • Ratios at 47:1 and 63:1 • Zero backlash • High torsional and tilting stiffness To find what you’re looking for, check us out on the web, or give us a call.

diequa.com/dw 800-359-4590

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Product World

Precision Components See us at:

Photo Etched Parts

BIOMEDevice - San Jose, CA MD&M West Anaheim, CA BIOMEDevice - Boston MA

• Intricate components as thin as .0005" • Eliminates cost of hard tooling • Eliminates burring and stress problems • Short lead times • In-house forming, laminating and plating • Prototype through production Download Capabilities Brochure

Dual-Axis AKD 2G Servo Drive

Flex & Rigid-Flex Circuits

Kollmorgen kollmorgen.com

• Medical, Aerospace and Telecom markets • Adhesiveless construction • Selective plating of gold and tin • SMT and through hole component assembly • Package sizes down to 0201 and .4mm pitch • Microvia sizes down to .001" diameter

The dual-axis AKD2G is a power-dense industrial servo drive that reduces mains wiring, fuses, and filtering to save significant panel space and cost. The AKD2G features

Download Flex Circuit Design Guide

expandable I/O (without increasing the size), removable memory, dual-channel STO, and the first drive-resident graphic display in the

EMI/RFI Shielding

industry.

• Global supplier standard and custom products • Commercial and military markets • Over 100 finger stock gasket profiles • Shielded vents and filters • Conductive foam and elastomer gaskets • Board level shielding

Other highlights include: Workbench

interface, optimized hybrid connector, and speed – its multicore Compute Engine, Servo on a Chip, is far more powerful than other servo drives. The AKD2G’s current loop update rate of 1.28 µs accommodates

Download Shielding Catalog

changing load conditions immediately. Velocity and position loops updates are also market leading at 62.5 µs and 125 µs.

www.tech-etch.com TECH-ETCH, INC., 45 Aldrin Road, Plymouth, MA 02360 TEL 508-747-0300 • FAX 508-746-9639 • sales@tech-etch.com

ISO 9001 AS9100D

REGISTERED

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Hydraulic Servo &

Proportional Valve Repair

Servo Kinetics (SKI) has been in business for 40 years, before many of the competitor’s even existed. Our capacity for servo and proportional valve repair far exceeds any of our competition. SKI serviced the NASA Houston Shuttle Simulator for 25 years, through three major upgrades of the Electro-Hydraulic, closed loop motion system.

The shuttle used 12 servo valves on “closed Loop” precision actuators. We suggest you visit our website for further details on our complete services, there are reference letters there you can read from FedEx, L3, Cedar Point, Fidelity and Delta Airlines. If you want/need a vendor that can meet any hydraulic challenges you have, SKI can do that for you. We know how to meet your needs.

INITIAL RUN-IN PERFORMANCE/FAILURE ANALYSIS THAT IS DOCUMENTED AND INCLUDED ON FINAL TEST REPORT SENT BACK WITH YOUR VALVE.

VALVE IS CLEANED ULTRA-SONICALLY, ALL INDIVIDUAL PARTS ARE INSPECTED FOR WEAR OR CRACKS. DYE CHECKING IS USED IF PART DANAGE IS SUSPECT.

FINAL PERFORMANCE TESTING INCLUDES TOTAL INTEROGATION OF ALL THE VALVES ORIGINAL PERFORMANCE CHARACTERISTICS.

DYNAMIC PLOT OF INPUT VOLTAGE VERSUS OUTPUT FLOW SENT BACK ALONG WITH COMPUTER GENERATED FINAL TEST REPORT.

DATA OF ALL PLOTS AND TEST REPORTS ARE RECORDED AND RETAINED FOR FUTURE REFERENCE IN OUR TESTING DATA BASE.

www.servokinetics.com

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POWER TRANSMISSION-PART CONVEYING

PYRATHANE® BELTS Lifetime Warranty Against Manufacturing Defects

Product World

SAMPLES AVAILABLE

Pyramid Pyrathane Belts® — the standard of the industry! Try them on your conveyor.

CUSTOM MADE IN INCH, METRIC & O-RING SIZES Round, Flat and Connectable Polyurethane Belts • Very Clean Operation • Eliminates Tensioning Devices • Exceptional Abrasion Resistance AN ISO 9001 CERTIFIED COMPANY

SIL 3/PL e absolute positioning with one sensor Pepperl+Fuchs pepperl-fuchs.com This positioning system achieves SIL 3/PLe compliance

pyramidbelts.com

with a single sensor, making them uniquely safe and

641.792.2405 • sales@pyramidbelts.com

highly efficient. While previously associated with high cost and time investment, this safety level can now be

19Pyramid_4x475_lineShaft.indd 1

Rod Ends and Spherical Bearings designed and manufactured to Aurora’s exacting standards for quality and durability.

12/3/2018 12:18:16 PM

Your Partner moving forward! Registered and Certified to ISO_9001 and AS9100. From economy commercial to aerospace approved, we’ve got it all!

attained more simply than ever before. The safePGV and safePXV systems are based on a technology that has been used for many years — the particularly reliable combination of a 2-D reader and Data Matrix code. New superimposed Data Matrix codes, one in red and one in blue, are the hallmark of the safety version.

The 2-D reader is also equipped with red and blue

LEDs. The two-color Data Matrix codes, in combination with two-color LEDs on the reader, are the basis for this unique security solution. Each individual code contains position and safety information, which is made visible by red or blue LED illumination and can therefore be read by the camera.

The new safePGV system is the suitable solution

for navigation with automated guided vehicles (AGV) in the fields of warehousing and material handling, supply, and production. In addition to the safe X position, the sensor supplies all values required for

R

reliable vehicle control. In automotive manufacturing, for example, a minimum distance can be guaranteed

Aurora Bearing Company 901 Aucutt Road Montgomery IL. 60538

between vehicles at all times, protecting all the employees working in that area.

complete library of CAD drawings and 3D models available at:

w w w. a u r o r a b e a r i n g . c o m

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Drive And Controls For Any Application Whether you’re designing a simple conveyor or planning a complex system, you can rely on Interroll for your conveying needs. Our drives and controls are crafted with precision and engineered to deliver outstanding performance and reliability. The Interroll EC310 24V brushless RollerDrive can be paired with different Control Cards, depending on your application: EC310 & DriveControl Card EC310 & ZoneControl Card EC310 & MultiControl Card

Simple motor control. Simple ZPA conveyor line, some external I/O. State-of-the-art conveying and controls, monitor signals, track packages, adjust speeds on the fly, interface to a PLC, create custom package movements. UL Listed.

Visit interroll.us to learn more about our solutions.

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ELIMINATE BACKLASH BY USING HELI-CAL® MACHINED FLEXURE COMPONENTS Flexible Couplings

·

Machined Springs

·

U-Joints

Features: •

Eliminate elastomeric elements like rubber bushings, spiders, rubber discs and pads

No maintenance, no backlash, no lubrication, constant velocity, and smooth bearing loads.

End attachments can include tangs, clamps, flanges or threaded ends.

Applications: • • • •

Machine Tools Encoders CNC Machines Motors

• • •

Power Generation Instrumentation Robotics

Industries: • • • •

Aerospace & Defense Agricultural Automotive Industrial & Manufacturing

• • • •

Commercial Medical Petrochemical Recreational

w w w. he li- ca l .co m

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Product World LBL series linear actuators SMAC smac-mca.com LBL series linear actuators’ design features flat printed coil and single-piece, screw down magnets. It’s equipped with SMAC proprietary encoder and gives more than 100 million cycle expected life. Starting with stroke length of 25 mm and 50 mm, the range will extend up to 200 mm.

The LBL series generates peak force 60N and is capable of

accelerations over 50G. The LBL can be integrated into Stack electric manifold actuators for OEM multi-actuator stations. The SMAC Stack design does the same thing for actuators that manifolds did for air valves automating multiple axes with a built-in controller option via CANopen, Ethernet/IP, and EtherCAT.

DESIGN WORLD

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Product World Schmidt controlflex couplings Ruland ruland.com Controlflex couplings have a compact balanced design, are electrically isolating, and have high misalignment capabilities, making them a suitable fit for encoders or light duty power transmission applications. Equipment designers in industries such as packaging, semiconductor, solar, medical and

Features:  •

vibration at speeds up

automation benefit from the wide range of sizes and performance characteristics offered by these couplings.

Controlflex couplings are comprised of two anodized aluminum hubs joined by pins to a Delrin

insert called the frog. Hubs are manufactured in standard widths for general purpose applications and thin widths for compact installations. The Delrin frog allows for a balance of rigidity to maintain position and flexibility for high misalignment capabilities. It is an efficient torque transmitting element

Balanced design for reduced to 25,000 rpm

High misalignment capabilities

Single frog design for higher misalignment capabilities

Double frog design for higher torque capabilities

with light bearing loads.

Controlflex couplings are available in clamp screw designs with or without keyways in inch,

metric, and inch to metric bore sizes ranging from 1/8-in. (3 mm) to 1 ½-in. (40 mm). Hardware meets or exceeds DIN 912 12.9 standards for maximum torque capabilities.

ORION FANS Specialty Filters for Louvered Guards and Filter Fan Kits

We’lla make We’ll make. YOU fan. YOU a fan.

First in Louvered Filter Fan Kits The industr y’s lowest cost louvered filter fan kit now includes easy access slide and hinged guards for installing and replacing filters. Assembled filter fan kits offer an IP55 or IP56 rating. The heavy-duty guards feature UV protection and reduce maintenance time and cost. • Protects against dust, dirt and moisture • Kit includes fan, louvered guard, filter, metal guard and hardware

High Density, Water Resistant & Fire Protection Filters • Works with snap-on, slide or hinged louvered guards • Meets certain MERV ratings for HVAC applications

• Louvered guards are IP54 rated with UV protection • Fits 80, 92, 120, 172, 180, 200, 225 and 280mm AC & DC fans

Find it. Spec it. Buy it.

AC & DC Fans - EC Fans - AC & DC Fan Trays - AC & DC Motorized Impellers - Fan Accessories

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1/7/19 2:16 PM DESIGN WORLD

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Safe solutions for your industry

The DNA of Safety.

Programmable Safety Controller PROTECT PSC1

■ Modular structure for application flexibility ■ Expansion up to 272 inputs/outputs ■ Ethernet SDDC (Safe Device to Device Communication) ■ Safe drive monitoring for up to 12 axes ■ Universal communication interface for all common field bus systems

Machine safety is a complex topic. Companies are increasingly calling on qualified specialists for support. For Schmersal, safety is in our genes – The company is now managed by the third generation of the Schmersal family. But that’s not the only reason machine safety is part of our DNA: 70+ years of competence and expertise allows us to combine the building blocks of safety-rated components with control systems and software for customized and comprehensive safety systems. Schmersal provides solutions for reliable safety signal processing based on safety control modules and safety controllers with an array of visualization and diagnostic possibilities. The new PROTECT PSC1 is a programmable, modular safety controller which includes the development of custom applications and their integration into higher-order control systems. The PROTECT PSC1 system consists of a reliable, compact freely programmable safety controller and dependable extension modules; fitted with a universal communications interface to allow data exchange across different fieldbus systems with higher level controllers. In developing the new PROTECT PSC1, we have taken a big step forward in the field of control technology and its unique features clearly set this control system apart from other solutions.

www.schmersalusa.com | 888-496-5143 | salesusa@schmersal.com Schmersal 1-19.indd 211

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www.neugart.com

Neugart_REV (2)_1-17.pdf

1/18/19 9:50 AM


Product World

Flange linear ball bushing line NB nbcorporation.com This flange linear ball bushing line offers the

Seamless Integration of PHD Grippers to Universal Robots

benefits of a slide bush with the mounting ease of a flange. When an application calls for ease of assembly, users can select a completely integrated system. Single, doublewide, or center mount configurations are available. Flange types are available in inch, Asian, or European metric dimensions.

Pneu-Connect® is a pneumatic end-effector system that provides seamless integration for Universal Robots and other collaborative robots at a third of the price of its electrical equivalents.

There is an extensive variety of flange bush combinations to choose from. Detailed drawings and tables provide dimensional and mechanical information. Now also available in 3-D CAD.

Pneu-Connect is easy to attach and control a pneumatic end effector to a Universal Robot utilizing on-board MAC directional control valves, requiring only a single air line and the tool port of the robot. The Pneu-Connect package includes the end-effector, a cuff that connects directly to the robot arm, and “URCap” software—an application specific to the Universal Robot.

Easy

End Effector Integration

Pneu-Connect®

Pneu-Connect® X2 Series GRH Series GRT Series GRA Series GRV Series GRL

Freedrive button on bottom for easy position programming

Watch “PHD Pneu-Connect Overview” on the PHD, Inc. channel at youtube.com

1-800-624-8511 DESIGN WORLD

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for more information, visit:

phdinc.com/pneuconad

P.O. Box 9070 • Fort Wayne, IN 46899 USA

1/20/19 2:38 PM


Product World Corner-mount interior LED lamp Optronics optronicsinc.com The ILL38CMB Corner-Mount Interior LED Lamp is a modular, low-profile lamp that can be installed in virtually any trailer as original equipment or as an aftermarket upgrade.

This LED Lamp relocates a vehicle’s critical interior lighting sources away from the high-traffic central core of a vehicle, where they

are vulnerable to potential harm, and reorients them to the corners of a vehicle’s ceiling. A corner location keeps the lights away from potential threats, while providing opposing beam directions that reduce shadows and dark areas, enhancing overall interior illumination quality.

The new multi-volt lamp is compatible with both 12- and 24-volt electrical systems. The lamp operates in both refrigerated and

non-climate-controlled environments and has an operational range of between -4 and 140° F (-20 and 60° C). The ILL38CMB CornerMount Interior LED Lamp is expected to be available at the end of the first quarter of 2019. Lenses and housings are made of tough polycarbonate material that is sonically welded, and the base is made of sturdy aluminum. The lamps employ a solid-state, surfacemount device (SMD) design that protects their electronics against moisture, shock and vibration.

Customizations & Accessories for your NEMA 4X / IP66 Nonmetallic Enclosures

HMI Cover Kits & Prop Arm

• Fiberglass Reinforced Polyester (FRP) or Polycarbonate enclosures • Lightweight • Non-corrosive • Non-conductive • UV resistant

NEMA 4X Vent Kit

ULTRAPLUG® Hole Plugs

• 3D model library for easy download Connect with us online!

222 North Union Street • Bryan, Ohio 43506 Ph: 800-722-2679 • Fx: 800-237-7269 © 2018 Allied Moulded Products, Inc.

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Modifications

• Modifications include: – Custom holes & cutouts – Color matching – Silk screening – EMI/RFI shielding – And many more!

Scan to learn more about Allied Moulded and the latest in nonmetallic enclosures & accessories.

www.alliedmoulded.com 1/16/19 12:32 PM


Thanks to you…. for making 2018 the best year to make 2019 even better….RelChip Inc, is NOW positioned to take the microelectronics market by storm with a family of products that are unmatched and unequaled. RelChip is the global leader of disruptive technologies with up to a 10year : 1year product life as compared to closest competitor in this industry of Extreme Microelectronics-HT, Reliability Life-Cycle Performance, with exceptional competitive pricing. Whatever your needs, RelChip has the Products and Services to help support your needs:

INDUSTRY:

PRODUCTS:

Semiconductor, engineering, and manufacturing of extreme environment/high temperature microelectronics. When integrated circuits demand the highest levels of reliability and performance; for the Aerospace (military & commercial off the shelf COTS), energy oil & gas exploration, geothermal technology, and the utility markets.

    

ARM® Cortex-MO® based 32-bit microcontroller Static random access memories (RAM) Logic ASICS RAD resilient / Trusted Fab

CONTRACTS & SERVICES:

TECHNOLOGY:  Operating temperature range from -55° to 300°C (-67° to 572°)  Increased Enabling applications  Consistent, reliable, performance in the most extreme environments

Strategic partnering/teaming on complex projects Critical design and manufacturing services Government & major Corporate projects Predictable reliability 5 years at 225°C, 1 year at 300°C  COTS and custom design    

Call us today to get started on achieving your goals.

Ken G. Riley, Vice President, Business Development kriley@relchip.com | +1.949.444.4877 | 506 W 8300 S, Sandy UT 84070 | RelChip.com

• AS 9100-D Certified

• National LEAP Design Innovation Finalist

• TRACE/TRAC Certification

RelChip® is the industry leader in reliable, -55°C to 300°C SOI integrated circuits including microcontrollers, RAM and other logic devices.

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Product World

NEW!

PowerPlus hybrid stepper motors

BACKLIGHT CONVEYORS FOR INSPECTION & ROBOTICS APPLICATIONS

MOONS’ Industries moonsindustries.com

qcconveyors.com

PowerPlus Hybrid Stepper Motors eliminate the hassles of resizing motors by providing 25% to 40% more torque across the entire speed range of a motor. With the same physical dimensions as standard NEMA 23, 24 and 34 stepper motors, PowerPlus Hybrid Stepper Motors often drop into place to minimize upgrade costs while improving performance.

The increased torque of the PowerPlus technology is from

higher motor efficiency. In a conventional stepper motor, some of the torque-producing flux that links the rotor to the stator is formed outside the stator teeth. The stray flux wastes power and adds little to motor torque. A higher magnetic flux density within the motor increases the performance of the PowerPlus Stepper Motor, enabling it to generate up to 40% more torque than conventional motors. Magnets placed between the stator teeth redirect and refocus most of the stray magnetic flux into the stator teeth to produce additional torque with the same input power.

3” and 4” ROUND TFTs WITH CAP Touch Panels

NEW ROUND DISPLAYS WITH OR WITHOUT CAP TOUCH PANELS! 3” or 4” FULL COLOR TFT

Data Image USA - www.dataimagelcd.com - 407.478.4064 heldred@dataimagelcd.com - Data Image USA on

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Product World New ICs for step-motor control Performance Motion Devices pmdcorp.com

The Juno Step Motor Control Integrated Circuits (ICs) is now available in a 56-pin VQFN package. The new Juno Step Motor Control IC is the latest addition to the Juno Velocity and Torque Control IC family. The industry’s first family of compact ICs with full four-quadrant motion control; direct input accepted from quadrature encoders; profile generation; and advanced current control.

Juno ICs are for designs with limited space

that need to control noise, vibration, and power consumption. Juno ICs are also easy to deploy with embedded motion commands and onboard intelligence.

Performance Medical Devices recently

released the Juno Velocity and Torque Control IC series — the industry’s first family of compact ICs with full four-quadrant motion control, direct input quadrature encoder, profile generation, and advanced current control.

The Juno Step Motor Control IC 56-pin

VQFN package has the highest PWM frequencies offered by Performance Motion Devices and the smallest IC parts — measuring 7.2 x 7.2 mm. Juno Step Motor Control ICs are available both with encoder input and without.

The Juno Step Motor Control IC also comes

with numerous safety features including stall detection, over- and under-voltage sense, overcurrent detection, over-temperature, and i2t current foldback. Coupled with compact MOSFETs, the Juno Step Motor Control IC can replace older step motor amplifiers and dramatically reduce the size and heat output.

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REMARKABLY RUST RESISTANT

EXTRAORDINARY FITTINGS Brennan is the industry leader when it comes to corrosion resistant tube fittings and adapters. Every Brennan fitting exceeds the S.A.E. corrosion resistance standard, some up to 23 times! Because we control the manufacturing process from end-to-end, we can offer the widest variety of sizes, materials, platings and coatings for whatever level of protection your application requires - even custom engineered solutions. CALL US AT 800.331.1523 Brennan Industries 10-18_FPW.indd 219

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Product World Kit encoder range expansion POSITAL posital.com POSITAL is expanding its line of kit encoder solutions for motion control applications to satisfy a wider range of needs faced by machine builders, system integrators and motor manufacturers. Kit encoders are component-level products, designed to be built into motors or other types of equipment where real-time measurement of rotary position (angular displacement) or rotational speed is required.

Kit encoders typically lack sealed housings, ball bearings or separate shafts. Instead, they are intended to fit inside the host

machine’s casing, with rotating components connected directly to the machine’s shaft. This results in rugged, compact installations with direct measurement of rotational position and speed. The kit encoder line will now include: • Multi-Turn Battery-Free Magnetic Kit Encoders

• Compact Incremental Optical Kit Encoders

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For further information about products on these pages visit the Design World website @ www.designworldonline.com

Microcontroller-based brushless dc motor controls American Control Electronics americancontrolelectronics.com The PML Series is a family of versatile, configurable controls for brushless dc motors. PML drives can control motors that range from 90 to 280 Vdc, up to 5 amps/1.5 HP, using either 115 Vac or 230 Vac line sources. On-board trim pots allow operators to quickly set maximum and minimum speeds, acceleration and deceleration rates, motoring and regening current limits, as well as the proportional and integral feedback gains.

An onboard microprocessor allows for custom programming the PML

Series for tasks as simple as changing the purpose of a jumper or trim pot, or as complex as programming an entire application-specific routine. Features: • UL 61800-5-1 listed (NOTE: this standard will obsolete UL 508C in 2020) • NEMA 4X packages available in both steel and plastic • Doubler mode: Able to convert 115 Vac input into 280 Vdc output. • Isolated inputs: Accepts floating or grounded signals 0 ± 5 Vdc, 0 ± 10 Vdc or 4-20 mA • Diagnostic LEDs: LEDs for power and status (e.g., undervoltage, overvoltage, short circuit/current trip, overheating warning/trip) • Thermally protected: Drive recognizes when overheated as a result of overload • Hall effect sensors: 120°, 5 Vdc, 75 mA combined

DESIGN WORLD

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Key Bellevilles, Inc. LARGEST MANUFACTURER OF DISC SPRINGS IN THE WORLD Live Load with Belleville Disc Springs LARGEST STOCK OF STAINLESS STEEL AND INCONEL SPRINGS IN THE WORLD HIGH TEMPERATURE FLANGE BOLT

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Entry-level PC-based controller Beckhoff beckhoffautomation.com The new CX7000 Embedded PC from Beckhoff opens up the convenience and efficiency of the TwinCAT 3 software

Immediate Delivery! 24-Hour Service 7 Days a Week!

environment to highly compact, DIN rail-mounted controllers. This further enhances the scalability of PC-based control

Tel: 724-295-5111 Fax: 724-295-2570 Toll Free: Tel: 800-245-3600 Fax: 800-847-1672

Visit our Website: www.keybellevilles.com for a FREE Design CD-ROM

Product World

technology from Beckhoff – ranging from mini-PLCs to manyLIVE LOADING VALVE PACKING GLANDS

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core Industrial PCs. An advanced 400 MHz processor and builtin configurable I/Os mean this Embedded PC delivers an ideal price/performance ratio.

Equipped with an ARM Cortex-M7 processor (32 bit, 400

MHz), the CX7000 Embedded PC makes considerably higher processing power available in the low-cost, compact controller segment. Furthermore, all the advantages of the TwinCAT 3 software generation can be utilized. The extremely compact design of the CX7000, with dimensions of just 49 x 100 x 72 mm, ensures optimum scalability of PC-based control for small controller applications that typically require minimum footprint.

If left to your own devices, this is where you hope the pumps & compressors were sourced. NittoKohki.com

Features •

Eight digital inputs, 24 Vdc, 3 ms filter, type 3

Four digital outputs, 24 Vdc, 0.5 A, 1-wire technology

These integrated multi-functional I/Os can be configured for other operating modes via TwinCAT 3, including the option to use fast counting or processing of analog values:

Counter mode: 1 x 100 kHz digital counter input, 1 x digital input as up/down counter, 2 x digital counter outputs

Take heart engineers: • Exceptional reliability y • Low noise & vibration n • Long service life • DC-motor driven

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Product World Drum cover keeps bulk material contained and free of contaminants EXAIR exair.com This fine mesh non-woven drum

Your Problems

cover is designed for use on 55 or 30 gallon drums. The breathable

With 164 different modules that connect to create a Cube67+ system, Murrelektronik can turn your problems into solutions. Cube67+ allows for absolute flexibility in system design while our One Cable Technology for bus & power saves time & money during installation.

material allows the air from an air operated conveyor to circulate whether moving material in or out of a drum. The drum cover prevents contamination of material

Our Solutions

and keeps material contained in the drum for a cleaner and safer work environment. Because it is fabricated to fit 55 or 30-gallon drums, it is the simplest of solutions when needing a

Digital Input

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containment vessel for transferred scrap, trim waste, parts, chips or pellets. It is suitable for conveyance hoses from ž-in. (19.1 mm) up through a 3.4-un. (86.4 mm) outside diameter.

Safety Output

Analog Input or Output

Line Vac conveyors are a low-cost way to transport complex shapes,

bulk solids and waste — with no moving parts or electricity. Units eject a small amount of compressed air to produce a vacuum on one end and high output flows on the other with instantaneous response. Air speed is easily controlled by regulating inlet air pressure. Valve Connection Module

IO-Link Master

Line Vacs are available in aluminum, Type 303SS, Type 316SS and

hardened alloy to resist abrasion in sizes from 3/8-in. (10 mm) through

M12 or M8 Connections Freely Configurable Ports | LED Diagnostics

5-in. (127mm). They come in styles for use with hose, threaded NPT for use with pipe and a sanitary flange model for use with flanged pipe. The drum cover comes complete with hose clamps and a durable spring buckle strap for quick and easy installation.

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For further information about products on these pages visit the Design World website @ www.designworldonline.com

Industrial cables for Ethernet applications Telegärtner telegaertner.com These UL-listed industrial cables for Ethernet applications are well protected against harsh industrial environments and outdoor applications and is available pre-terminated and as bulk cable. The cables are oil and UV resistant and are the perfect choice for access control systems, video surveillance, outdoor WLAN access points, and many other applications.

These robust cabling solutions for industrial Ethernet applications are

protected against the rigors of harsh environments by a PUR outer jacket. The industrial patch cords RJ45-RJ45 AWG 26/7 are oil and UV resistant and are suitable for harsh industrial environments or outdoor applications. This also makes them a suitable choice for mobile radio, outdoor access points or outdoor cameras (CCTV).

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Product World Connector for outdoor applications LEMO lemo.com The Anglissimo connector for outdoor applications has a new connector design. The T series, available in size 0T, 1T and 2T is watertight with an IP68 protection class. The Anglissimo is an elbow plug connector that prevents cable cutter by easily adjusting the cable output position during its assembly.

Composite Metal Wire for High Strength • High Conductivity Biocompatible • Radiopaque • Solderability • Flexible • Kink Resistant • Cost Effective Alternative to Solid Precious Metal W ire

Electronic and Medical Devices Combine two or more metals or alloys into a clad metal wire “system” that acts as one.

info@anometproducts.com • (508) 842-3069 • www.anometproducts.com 226

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The Step Motor Specialists BACKED BY

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Product World Rotary seal increases productivity in process applications Freudenberg freudenberg.com The Gerromatic rotary seal has a wave-shaped sealing lip that increases the maximum amount of pressure that can be applied. The sinusoidal contact path also reduces friction and provides self-

Don’t Get Caught In a Labyrinth of Bad Seals Our Patented Centrifugal Pressure Seals: ✓ Keep lubricants in and contaminants out ✓ Reduce down time

cleaning, which extends operating life.

In the process industry,

including the food and beverage sector, shaft seals used in equipment mostly have a rotation-symmetrical seal lip, which abuts the rotating shaft with a groove-like contact pattern. During wet-running, this can cause the medium to be displaced at the contact surface. The seal then runs in a more or less dry condition, leading to increased friction and higher temperatures. The increased friction increases wear and reduces the efficiency of the equipment.

✓ Support horizontal and vertical applications

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a rotation-symmetrical design. This results in a sinusoidal contact pattern. As

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usual temperature rise at the sealing area. The contact zone of the undulated

✓ Support extremely low-viscosity fluids

pressure so the seal lip’s performance is maintained. It lies securely against

The Gerromatic is specifically designed for wet-running applications

and pressures up to 8 bar. It is equipped with a wave-shaped sealing lip, not the shaft rotates, each point of the seal lip repeatedly coats a different area of the shaft, moistening it with the medium. This reduces friction and the seal lip, alternating between flat and linear, has the ability to distribute high the shaft and does not fold down, even across a wide range of pressures. Furthermore, the sinusoidal path provides self-cleaning: If small particles, perhaps from the process material, settle under the seal lip at times, they are quickly rinsed out of the contact zone. This reduces wear and increases the operating life of the seal.

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centritecseals.com 860-643-1531 228 January 2019 www.designworldonline.com Product World 1-19 Vs3.LL.indd 228

DESIGN WORLD

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Your trusted partner in traceability

Download our new traceability white paper

The complexity of building a robust, real-time traceability system can be overwhelming. Successfully upgrading your current automated systems or making the transition from a manual system requires having a clear understanding of what traceability entails. At Omron, one of our major goals is to make traceability as intuitive and accessible as possible, so that you can implement workable systems and comply with relevant standards with ease.

Download our new white paper to learn all the essential components to solve traceability challenges, which will set the foundation of a more comprehensive understanding of this crucial manufacturing practice. Visit our link below to discover strategic solutions for traceabilityrelated challenges. www2.omron.com/whitepaper_dw

We’ve found that simplifying the way we think about traceability can help make the traceability process easier. We call this concept “MVRC,” which stands for “Mark, Verify, Read and Communicate.”

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Product World Cast-iron three-phase ac motor AutomationDirect automationdirect.com MTCP2 industrial duty motors meet the premium efficiency requirements of the Energy Independence and Security Act of 2007. MTCP2 motors are offered in T-Frame (1 to 300 hp) and TC-Frame/C-Face (1 to 30 hp). C-face kits are available for motors over 30 hp.

These motors are available in 1200, 1800, & 3600 RPM and have TEFC

(Totally Enclosed Fan Cooled) enclosures with cast iron frame and ribbed design for maximum cooling. The motors feature full length, cast iron mounting feet, steel fan cover, and cast iron junction box with rubber gasket and rubber dust cover.

MTCP2 motors have premium quality ball bearings (1-75 hp) or roller bearings

(100-300 hp) with maintenance free bearings on 10 hp and below. V-ring shaft seals are used on the drive end and opposite drive end. The motors are electrically reversible and have Class F winding insulation.

230 January 2019 www.designworldonline.com Product World 1-19 Vs3.LL.indd 230

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More than 380 pages of parts, pricing and specifications. Call: 888-SPRINGS (888-777-4647) Visit: leespring.com Fax: 888-426-6655 Email: sales@leespring.com

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FOTOFABULOUS PARTS For over 50 years, Fotofab has been delivering the best photo-etched, formed and stamped metal components. We maintain a focus on customer service and a high level of quality. With tolerances exceeding the demands of our customers, print-to-prototype parts in 1 day, and a can-do attitude. We do what we say and honor what we said.

Common Parts: - EMI/RF Shields - Optical Encoders - Electrical Contacts - Filters & Screens and much more!

Standard & Exotic Metals Forming & Stamping for larger production runs Value Added Finishes

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Product World ASIL-certified BLDC system basis mosfet driver Allegro MicroSystems allegromicro.com The AMT49105 is the newest ISO-26262 compliant N-channel power MOSFET driver. The AMT49105 simplifies motor systems designs and provides footprint reduction by integrating power analog systems requirements.

With a robust output gate drive, this

device can be used in a range of applications, including power applications >1KW. Additionally, the AMT49105 provides the LIN transceiver, regulated microprocessor supply, phase monitors for sensorless BLDC control and other unique features that reduce overall power consumption required in today’s efficient vehicles.

The AMT49105 is a suitable fit for

high-power inductive safety automotive and industrial applications, like engine cooling fans, braking and multiple pump applications where supplies range from 5.5V to 50 V. Advanced diagnostics monitor and indicate system faults, internal faults and power bridge faults to assure safe systems operation. The AMT49105 is designed to the ISO-26262 standard and is compliant to an ASIL-B level.

DESIGN WORLD

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Secure Your

Connection

Product World

The premier supplier of power system components worldwide, Interpower® presents an innovation of safety and security with the new Interpower Connector Locks.

Cables enhanced with XLPE insulation Helukabel helukabel.com

To help prevent accidental power interruptions, secure your cord set to a power inlet or outlet with the new Interpower Connector Locks. This system provides the security and stability necessary to help protect your equipment in numerous applications, including medical and information technology.

Select TOPFLEX and TOPSERV VFD cable products have had their conductor insulation material upgraded to XLPE from PVC/nylon to stay ahead of the curve as the industry transitions towards a new electrical installation code. The update will require the use of RHH, RHW, RHW-2, XHH, XHHW and XHHW-2 insulation. The product specific cable types being upgraded are: TOPFLEX 600 VFD,

1-week U.S. manufacturing lead-time on non-stock Interpower products

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drive systems and servo drive systems shall be listed flexible motor supply cable

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equipment manufacturer’s instruction.”

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There has been a change to Chapter 4, Article 4.4.2.8 - Circuits Supplied

equipment supplied by power conversion equipment as part of adjustable speed marked type RHH, RHW, RHW-2, XHH, XHHW, or XHHW-2 or selected based on

To date no motor manufacturers have specifically required XLPE insulation

for general VFD wiring applications. The general interpretation of the current 2018 NFPA for wiring with regards to Chapter 4, Article 4.4.2.8 is that cables using these insulation types are intended for use inside the panel where the

®

wiring is contained between the drives and protection equipment (of the panels) ®

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1/16/19 12:44 PM


Automation & Control Freak? Same here.

We carry more automation & control brand names than any other distributor in North America. It’s true – we checked.

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Product World

No Kinks No Hose Twisting

Simplified hose configuration, less hose and adapters combine to reduce repairs and downtime cutting the overall cost of hydraulics.

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Hydraulic Live Swivels Inline & 90°

The M12-X product line now has a female cable connector and RJ45 to female feedthrough for control cabinets. The M12 X-coded cable connectors are part of the 825 Series, which includes data transmission 4-paired up to 10 Gbit/s. The new connectors are available straight or angled with 8 gold-plated

Heavy Duty Ball Bearing Design

contacts. The M12-X offers an IP67 degree of protection with the RJ45 being rated IP20. Key applications include factory automation, food and beverage,

• Rated To 10,000 P.S.I. • Heat Treated • Available In 304 & 440 Stainless Steel • Custom Design & Sizes Available • Rebuildable Ball Bearing Design • Withstands Heavy Side Loads • Superior Quality Alloy Steel • Full Flow — Low Pressure Drop

packaging, and more. Features: •

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dESIgN SOLuTIONS

Design Solutions at your fingertips! Contact us for over 70 years of “in-house” design application and engineering expertise in: • Stamping • maChining • aSSembly • injeCtion molDing our team is just an email or phone call away. It’s what’s on the InsIde that counts ® E L E C T R O N I C S

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Product World

Standard Parts. Winco.

Piezotronics sensor for measurement in tight spaces PCB pcb.com The Model 105C pressure sensor is as robust as its larger sensor counterparts but compact enough to fit into small spaces or areas with

JW Winco offers stainless steel standard parts with high corrosion resistance, and the ultimate in material quality.

tight clearances. The small size and stiffness of a quartz-sensing element yields a high

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resonant frequency (> 250 kHz) for high quality measurements where other piezoelectric pressure sensors cannot fit or survive.

over models with connectors; it installs into

Bearing Protection that Outperforms all Others

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psi (690 kPa), it also has applications in wind tunnels with proper thermal protection. Additional

Helwig’s Bearing Protector extends the life of motors by keeping shaft voltage to a minimum. Prevents pitting and costly damage to bearings. The best choice for the motor industry.

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Ready for the Next Servo Revolution?

Sigma-7 Unshackles Automation Productivity Planning innovations for years to come? Or, are you more focused on next week’s productivity numbers? Either way, Yaskawa’s new Sigma-7 servo systems help you break free of yesterday’s standards. From the first spin of the rotor, Sigma-7 boosts precision and productivity. Yet, its programming ease and performance make tomorrow’s automation ideas possible. Don’t stay chained to legacy servo capability. Crank up to Sigma-7, the servo for the Next Revolution.

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Product World 4.3-inch display series Danfoss powersolutions.danfoss.com The DM430E Series Display will provide OEMs and operators with a modern machine interface with increased outdoor screen viewability, an environmentally robust design, simple screen

outstanding sunlight viewability and wide viewing angles. In darker

set-up and a range of flexible features. As the visual interface of

settings, the light sensor automatically adjusts screen brightness

the machine, the DM430E Series Display helps OEMs modernize

and switches between day and night display themes.

the overall operating experience while also increasing operator

efficiency — all without compromising on the need for durable

application, OEMs can directly set up the display without any

performance in extreme operating environments.

programming. The application connects more than 4,000 J1939

engine signals with a set of pre-defined screen graphics, saving

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Through the updated Engine Information Center (EIC)

development time and resources.

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Whether it’s our industry leadingCARLO solid state relays and con- Contact us today, and one of our field sales representatives will GAVAZZI Automation Components tactors, our our vast range of sensors, motor controls, energy show you why we are one of the fastest growing automation USA Tel: 847.465.6100 Fax: 800.222.2659 meters and current-, voltage- andCanada 3-phase monitors, CARLO companies worldwide. We’ll even provide a free evaluation Tel: 888.575.2275 Fax: 905.542.2248 Tel and Fax:needs 55.5373.7042 GAVAZZI has the solution for your Mexico application sample to qualified OEMs. www.GavazziOnline.com • Info@CarloGavazzi.com twitter.com/CarloGavazziNA facebook.com/CarloGavazziNA

GavazziOnline.com • 847.465.6100 • Info@CarloGavazzi.com 240

Visit our website for downloadable data sheets, brochures and pricing: www.GavazziOnline.com

January 2019 www.designworldonline.com

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Delivering extremely small connectors, excellent signal integrity solutions and unmatched support.

High-Speed Shielded

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Cable Assemblies and Switches

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Product World

Industrial circular connectors for harsh environments Mencom mencom.com

[

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This complete line of circular connectors, including

]

but not limited to, M8, M12, ½-in.-20 and M23 threads and MINI-Change connectors (MIN) with 7/8, 1, 1 1/8-in. threads. For the higher voltage (600V) applications, Power Distribution PMIN series with 1-in. 3/8 thread is also available. According to their recent product announcement, the coupling nuts and housings of the cordsets for 1-in. and 1 1/8-in. threads have recently been redesigned to deliver the better connectivity and stability.

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circular connectors were originally designed for aeronautical and tactical service applications, they are becoming more commonplace in industrial applications that need the ruggedness of the MIL-Spec design, but do not need the military specifications.

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DESIGN WORLD

1/17/19 4:00 PM


NEW Network-Capable Absolute Encoder from EPC For EtherCAT communication in a precision absolute encoder, we’ve got your solution. EPC’s Model A58E series of EtherCAT-ready absolute encoders are designed for harsh factory environments. Available in both shaft and hollow bore, these encoders are easily designed into a wide variety of applications, and plug directly into a network with minimal prerequisites. They’ll work in various topologies, including bus, star, and ring configurations. The A58E series encoders work with CANopen over EtherCAT, so for users familiar with CANopen technology, implementation will be straightforward. As absolute encoders, they retain absolute position information even after a power loss, facilitating speedy system recovery at start-up without the need for system re-homing.

The A58E Series of Encoders offer: • • • •

58 mm packages Shaft or Hollow Bore construction Variety of mounting options Flexible, low-cost, and network-compatible industrial Ethernet solution • Maintains position information even in power-off scenarios • Up to 16 bits single turn resolution • Up to 43 bits multi-turn resolution

Encoder A58HE with Hollow Bore

PC or HMI EtherCAT Master

PLC Controller Servo Motor

A58SE with Clamping Flange (left) and Synchro Flange (right)

Call EPC today to learn how one of EPC’s EtherCAT absolute encoders can fit your application.

1-800-366-5412 | www.encoder.com Encoder Products 1-19.indd 243

1/18/19 10:15 AM


Product World Ultra-flexible thermocouple cables Cicoil cicoil.com

Standard Products Guide

Ultra-flexible thermocouple cables for temperature sensing applications excel when exposed to continuous flexing, torsion and tight routing.

Download Guide and Technical Support at sorbothane.com

in Type J and K versions with 1 to 8 conductors, and is good for use on control instrumentation, heating

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systems, cooking and baking, machine tools,

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injection molding, and automated equipment.

sorbothane.com

MADE IN U.S.A.

The 28 AWG thermocouple cable is available

The compact, flame retardant design is free of

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provide space & weight savings, high performance

6/12/17 11:24 AM

MAIN MANUFACTURING PRODUCTS, INC

and mission critical reliability. The patented extrusion process allows individually encased thermocouple pairs to be placed in a small flat profile, precisely controlling the spacing of each

HYDRAULIC FLANGES AND COMPONENTS

component, insulation thickness and the overall cable shape. The cables are available in continuous lengths, break-outs, custom formed shapes, cut to order, or as fully terminated assemblies.

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DESIGN WORLD

1/20/19 3:57 PM


Be more. Bringing to life great new solutions for complex applications. Whether you need a rotating union engineered to uniqe requirements, or a high-precision stock item, Deublin helps minimize your costs while maximizing your value to your customers. Visit WWW.DEUBLIN.COM to select and order your rotating union or slip ring today!

+1 847-689-8600 | cs@deublin.com | www.deublin.com

Deublin 1-19.indd 245

1/18/19 10:16 AM


Product World High force electric press actuators Curtiss-Wright curtisswright.com The FTP160 is the second frame size of the high-force electric rod-style press actuators and is designed exclusively for press applications. The Exlar FTP Series actuators allow machine builders to meet performance demands, while minimizing maintenance and downtime. Using planetary roller screw technology, the FTP Series provides high force in a small package.

With continuous force ratings to 200 kN (45,000

lbf) pressing, and speeds to 401 mm/sec (15.8 in/sec), and stroke lengths from 150 mm (6-in.) to 900 mm (36in.), the FTP Series can be applied across a wide range of pressing applications. Features: •

High capacity planetary roller screws offering up to 15X the life and significantly higher shock load resistance than a comparably sized ball screw

IP65S (min.) environmental protection

Idler pulley design greatly simplifies motor installation and belt tensioning / maintenance

Rigid circular front mounting flange simplifies installation

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1/17/19 4:02 PM


3 WAYS TO WIRE = 1 FAMILY

TOPJOB®S Terminal Blocks Now with Push-buttons and Levers!

• Choose the right version for your application: lever, push-button, or open tool slot • All three versions share the same Push-in CAGE CLAMP® technology for direct insertion of solid or ferruled conductors – no tools needed • Mix and match technologies on the same rail and share accessories (jumpers, marking, etc.) due to the same profile

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New TJS - Automation WAGO 12-18.indd 247World.indd 1

8/27/18 10:17 1:12 PM 1/18/19 AM


Product World Greases for ball and constant velocity joints Klüber Lubrication klueber.com Klübersynth J 87-20002 KR, is an automotive grease for ball joints, and Klüberlub HE 71-281, a low-friction grease designed for constant-velocity (CV) joints. Klüberlub HE 71-281 Friction in an automobile’s CV joints can lower efficiency as well as cause excessive heat, vibration, and noise. The low-friction additives in Klüberlub HE 71-281 minimize this friction resistance and boost CV joint efficiency. This special CV grease also lowers the temperature in the joint because of reduced friction. The high thermal resistance of synthetic components in the formulation enables the joint to operate reliably at elevated temperatures. Joints can even achieve short-term peaks up to 160°C. Klübersynth J 87-20002 KR A significant problem with ball joints in suspension and steering systems is a high static torque, particularly when joints experience long periods of rest. The friction from high static torque produces noise and a coarse operating feel. Using high viscosity silicone oil and PTFE as a base oil, Klübersynth J 87-20002 KR is designed to have ultra-low static and dynamic torques in both low-temperature and hightemperature environments. This low torque minimizes stick-slip tendency, micro friction noise and provides a smoother driving experience.

248 January 2019 www.designworldonline.com Product World 1-19 Vs3.LL.indd 248

DESIGN WORLD

1/16/19 12:49 PM


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Product World Your worldwide source for high performance Tapes, Films, Fabrics, and Silicone

Engineering Plastic Films

Mounting shaft collars Stafford staffordmfg.com These Mounting Shaft Collars include Flange Mounts with six mounting holes and a keyway plus the Accu-Clamp non-marring and perfectly square clamping feature for mounting a shaft, tube, or pipe to a flat surface or for attaching components to them. Additional solutions include Accu-Mount

Teflon™ PTFE Ultem® PEI Kapton®- HN, FN, XC Cirlex® PEEK™ DuPont® Mylar PET TPX® & Many More Slitting Die-Cutting Die-less Knife Cutting Adhesive Lamination Automated Sheeting Belting

Sold by Lineal Foot Available with adhesive No minimum orders

collars with precision locating hubs and predrilled and tapped holes, and conventional Face Mount Clamp collars with predrilled and tapped holes.

These Mounting Shaft Collars are available in aluminum, steel, and stainless

steel in 0.25 to 3-in. I.D. sizes, depending upon the part. The Accu-Clamp Shaft Collars have an integral clamp on one side while leaving the other flat and perpendicular within 0.001-in. TIR.

HMC series provides rapid termination technique Harting HARTING.com The Han ES Press HMC series provides suitable interfaces that can be installed quickly without tools and are extremely robust. The quick connect technology is dubbed the Han ES Press HMC, with the suffix ‘HMC’ standing for High Mating Cycles. The contact inserts are equipped with a pre-tensioned cage clamp which is triggered by an actuator. If the actuator is pushed into the contact chamber, the cage clamp returns to its original position and secures the conductor end. To

800-461-4161 sales@cshyde.com www.cshyde.com

release the connection, a screwdriver can be pushed into the actuator and the lever moved to the transition to the insulating body. The spring then once again releases the end of the conductor — for de-installation or when replacing components.

250 January 2019 www.designworldonline.com Product World 1-19 Vs3.LL.indd 250

DESIGN WORLD

1/17/19 4:03 PM

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Visit our new website! www.centuryspring.com

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Don’t see what you’re looking for? Contact our Custom Department.

1/16/19 1:21 PM


Manufacturers of Power Transmission and Motion Control Components

Product World Mounted bearings with spherical roller bearing solid-block housed units Timken timken.com Timken spherical roller bearing solid-block housed units with double-nut adapters are

Concentric Maxi Torque

designed for tough conditions without

Stock and Custom Keyless Hub-to-Shaft Connection System Email or call to get your CMT Stock Products Catalog Order today. Ships today!

being hard to use. The mounted units are stronger on the outside and smarter on the inside.

The spherical roller bearing solid-block housed units

now come in sizes up to 15-in. (380 mm), including the new TAA Series units, with added conveniences for customers. Inside each TAA Series unit is a double-nut, tapered adapter sleeve that simplifies bearing replacements in challenging environments.

Ergonomically advanced EASE-Z winch bars Kinedyne kinedyne.com

Custom Synchronous Drives

Precise. Reliable. Cost Effective. The EASE-Z Winch Bar is a Z-shaped winch bar that rotates 360°, providing users with greater leverage. The bar comes in one standard model and two combination versions that have modified handles that can be used to release tension on chain binders.

The heat-treated carbon-steel and mushroom-shaped head of the EASE-Z Winch Bar is tapered

for easy insertion, and helps keep the bar seated in the winch cap, and preventing it from slipping out during revolution and when the user is applying torque. A knurled non-slip handle with a flanged grip ring on the bar’s upper shaft helps prevent it from slipping out of users’ hands even in moist conditions.

Timing Pulley Stock

The Z-shaped EASE-Z Winch Bar can be rotated up to 360°, helping users position themselves

and the bar to deliver superior leverage when tensioning winch straps. The rotation of the bar

Guaranteed When You Need It.

without having to remove it from the winch cap eyelet provides a pivoting action that lets users quickly orient the bar as needed to avoid obstacles and to achieve optimum posture

Custom Machine & Tool Co., Inc. (800)355-5949•sales@ cmtco.com www.cmtco.com

while applying up or down force.

Precise. Reliable. Trusted. American Engineering • American Made © 2017 Custom Machine & Tool Co., Inc.

Product World 1-19 Vs3.LL.indd 252

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Wear-Free

Angle Measurement Made Easy

RFC 4800 Series of touchless sensors use a magnet attached to your application’s rotating shaft. Now with IO-Link output option, analog and IO-Link versions of RFC 4800 sensors can be easily connected with three wires—power, ground and signal. Touchless angle sensing technology excels in many applications including: • measuring through a wall or plate • shaft with limited play • sealed-shaft environments • low friction torque • high-vibration shaft • driveshaft misalignment

Magnet size selection and mounting as well as output choice are about the only parameters that need to be decided beyond those of track/wiper technology rotary sensors. Our technical specialists are happy to discuss your application needs.

Key specifications:

• Repeatability to 0.1° • Measures 0 to 360° • Resolution to 14-bit

• Linearity ≤ ±0.5% of F.S. • 2-ch. version option • speed output option

Free touchless angle sensors primer: www.novotechnik.com/rfc48 Novotechnik U.S., Inc. Telephone: 508-485-2244 Email: info@novotechnik.com

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SHACEY PETROVIC President & CEO; INSULET

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DTBoston19_housead_1-19.indd 56 477 DeviceTalks - Boston 2019_DW.indd

1/9/19 2:28 1:19 PM 1/16/19


S U M M I T

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The International Design and Development Event for Robotics and Intelligent Systems The Robotics Summit & Expo emphasizes the design and development of commercially viable robotics and intelligent systems products – wholly new products and services that are to be used outside of laboratory environments and sold at a profit. Dedicated tracks provide professionals with the information they need to develop the next generation of commercial class robotics and intelligent systems products and services. Robotics Summit Tracks Technologies, Tools and Platforms Design and Development Manufacturability, Business Models and Business Development Workforce Engagement and Development

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1/16/19 12:24 2:29 AM PM 1/9/19


A d I n de x 3D Systems ........................................ 23 Accumold ............................................ 199 ACE Controls ...................................... 22 Advanced Energy, Inc. .................... 124 Aerotech .............................................. 73 Airpot Corp. ........................................ 174 Allied Electronic & Automation ..................... Cov,3,235 Allied Motion ...................................... 189 Allied Moulded Products ............... 214 AllMotion .............................................. 4 Altech Corp. ............................. 27,29,31 Altra Industrial Motion Corp. ...............33,34,35,36 AMETEK DFS ...................................... 79 AMETEK Haydon Kerk Pittman ................ 83 Anchor Fluid Power ......................... 153 Anomet Products ............................ 226 Anritsu .................................................. 150 Apex Dynamics, USA ...................... 118 Applied Motion Products, Inc. ..... 26 Association for Advancing Automation ............249 Aurora Bearing Company ............ 206 Automation24, Inc. ........................... 9 AutomationDirect ............................. 1 Backer Hotwatt ................................. 75 Bansbach Easylift ............................ 96 Bay Associates Wire Technologies, Inc. ....................... 52 Beckhoff Automation ..................... 85 Bel Power Solutions ........................ 112 Beswick Engineering ...................... 190 binder USA ......................................... 7 Bird Precision ..................................... 209 Bishop-Wisecarver ........................... 101 Bodine Electric Company .............. 152 Boker’s Inc. .......................................... 45 BRECOflex CO., L.L.C. ...................... 166 Brennan Industries, Inc. ................. 219 Brother Gearmotors ........................ 131 C-Flex Bearing ................................... 209 Cadence Inc. ...................................... 93 Canfield Connector ......................... 192 Carlo Gavazzi ..................................... 240 Carlyle Johnson ................................ 126 CC-LINK PARTNER ASSOCIATION................................ 168 Central Semiconductor Corp. ...... 188 Centritec Seals .................................. 228 Century Spring .................................. 251 CGI Motion .......................................... 71 Chieftek Precision ............................ 50 CIT Relay & Switch ........................... 230 Clippard ................................................ 183 CMT ....................................................... 252 Coilcraft ................................................ 72 Components Corporation ............. 192 COMSOL .............................................. 63 CS Hyde Company ........................... 250 DATA IMAGE Corporation .............. 216 Data Modul Inc. ................................. 181 Del-tron ................................................ 90 Deublin ................................................. 245 Diequa .................................................. 202 Digi-Key ................................................ 15 DMIC ...................................................... 196 Dorner ................................................... 146 Eagle Stainless Tube ...................... 17 Electrocube, Inc. ............................... 127 Emerson ..........................................61,95 Encoder Products Company ........ 243 Equipto Electronics ......................... 246 EXAIR Corporation ........................... 5 Fabco-Air, Inc. .................................... 141 Festo ..................................................... 55 Fischer Connectors .........................103

DESIGN WORLD

AD INDEX - Leadership 1-19.indd 479

Flow Ezy Filters ................................. 151 Fotofab .............................................. 232 GAM ....................................................... 113 Gefran ..................................................142 Harmonic Drive ..................................185 Harwin .................................................. 59 HAWE Hydraulic ................................ 191 HBM, Inc. .............................................. 110 HEIDENHAIN CORPORATION ...... 160 HELUKABEL USA ............................. 51 Helwig Carbon Products, Inc ...... 238 HIWIN .................................... 193,195,197 HYDAC International .......................139 I-PEX Connectors .............................241 icotek Corp .......................................... 75 IDEC Corporation .............................. 65 IDS Imaging Development Systems GmbH .........................200 igus Inc. ............................................... 154 IKO International .............................. 169 Intech .................................................. 248 Interpower ......................................... 234 Interroll ............................................... 207 IronCAD ................................................ 97 ITT Enidine ..........................................198 J.W. Winco, Inc. ................................238 KEB America, Inc. .............................. 49 Keller America .................................... 41 Key Bellevilles .................................. 222 Keystone Electronics Corp. .................. 13,237 KHK USA ............................................. 140 Koford Engineering ........................ 201 Kollmorgen .......................................... 53 Kuebler ................................................ 133 Kuriyama of America, Inc. .............. 68 LAPP USA .......................................... 60 Lee Spring Company ..................... 231 LEMO USA, Inc. ................................ 138 Lenze Americas ............................... 143 Lin Engineering ............................... 227 Madison Co. ....................................... 170 Main Manufacturing ...................... 244 Maple Systems ................................ 132 Master Bond ....................................120 maxon precision motor .................. 32 maxon precision motor ......... Insert MEAN WELL USA, Inc. .................... 91 Memory Protection Devices ......... 21 METCASE .......................................... 221 MICROMO ..........................................IBC Miki Pulley US .................................... 18 Mitsubishi Electric Automation ................................... 94 MK North America ............................173 MOCAP ............................................... 246 Monnier ................................................172 Motion Index Drives ........................ 38 Murrelektronic, Inc. ........................ 224 MW Industries Atlantic Spring ............................. 30 MW Industries BellowsTech ................................. 57 MW Industries - Helical .................208 MW Industries - ServoMeter ....... 105 Nason ................................................... 111 NB Corporation ................................. 16 NBK America LLC ............................. 233 Neugart ............................................... 212 New England Wire Technologies ..................... 147 Newark element14 ............................ 121 Newcomb Spring ............................. 109 Nitto Kohki USA .............................222 NKK Switches of America, Inc. ................................. 56 Novotechnik .....................................253 NSK Precision .................................... 117

Ogura Industrial Corp. .................. 201 OKW USA ............................................. 119 OMRON Industrial Automation ................................ 229 OMS Motion, Inc. ............................ 242 Opto 22 ................................................ 77 Oriental Motor USA Corp. ............223 Orion Fans ....................................... 210 Parker Hannifin Corporation Pneumatic Division ................... 67 PBC Linear .................................. 42,43 PCB Piezotronics ............................130 Pepperl + Fuchs ................................89 PHD, Inc. ............................................213 Pilz Automation Safety L.P. ......... 161 POSITAL-FRABA ............................... 70 PRECI-DIP ..........................................159 Pyramid Incorporated .................. 206 QC Conveyors ................................. 216 R+W America ....................................157 RelChip .............................................. 215 Renishaw ...........................................137 ROLEC .................................................. 11 Rollon...................................................165 ROSS Controls .................................194 Rota Engineering Ltd. ..................218 RYCO Hydraulics ............................ 220 Schmersal .......................................... 211 Schneider Electric IMS .................. 167 Schroeder Industries ..................... 179 SDP/SI .................................................. 110 Serapid Inc. ...................................... 225 Servo Kinetics, Inc. ........................ 205 SEW-EURODRIVE ............................ BC SICK, Inc ............................................. 177 Siemens Industry, Inc. ....................171 Siemens PLM Software ..................69 Smalley Steel Ring ........................... 10 Smart Products USA ....................... 19 SMC Corporation of America ..... 217 Sorbothane ..................................... 244 STEUTE Industrial Controls ........ 125 Sunstone Circuits ......................... 203 Super Swivels ................................. 236 Tadiran ................................................. 25 Tech-Etch, Inc. ................................ 204 The Arthur G. Russell Co., Inc. ..... 28 The Lee Company .......................... 187 THK Corporate .................................. IFC Tolomatic ............................................. 47 Tompkins Industries, Inc. ............... 46 Tribal Manufacturing ...................... 120 Trim Lok ................................................ 84 US Tsubaki .......................................... 64 Veljan Hydrair ................................. 254 Wago USA ........................................ 247 Watlow ................................................ 148 Weintek USA, Inc. ............................. 80 Whittet-Higgins ............................... 149 Wittenstein ......................................... 39 Yaskawa Electric America .......... 239 Zero-Max, Inc. .................................... 2

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SALES Jami Brownlee jbrownlee@wtwhmedia.com 224.760.1055 Mike Caruso mcaruso@wtwhmedia.com 469.855.7344 Garrett Cona gcona@wtwhmedia.com 213.219.5663 @wtwh_gcona Bill Crowley bcrowley@wtwhmedia.com 610.420.2433 Michael Ference mference@wtwhmedia.com 216.386.8903 @mrference Mike Francesconi mfrancesconi@wtwhmedia.com 630.488.9029 David Geltman dgeltman@wtwhmedia.com 516.510.6514 @wtwh_david Neel Gleason ngleason@wtwhmedia.com 312.882.9867 @wtwh_ngleason Jim Powers jpowers@wtwhmedia.com 312.925.7793 @jpowers_media Courtney Seel cseel@wtwhmedia.com 440.523.1685 @wtwh_CSeel

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2019

Leadership in Engineering

3D Systems ..................................256 Accumold ......................................257 ACE Controls ................................258 Advanced Energy, Inc. ..............260 Aerotech ........................................262 Airpot ..............................................263 Allied Electronics ........................264 Allied Motion ................................265 Allied Moulded Products .........266 AllMotion ........................................267 Altech Corporation ....................268 Altra Industrial Motion ..............269 AMETEK DFS ................................259 AMETEK Haydon Kerk Pittman............261 Anchor Fluid Power ...................270 Anomet Products, Inc. ..............271 Anritsu Company .......................272 Apex Dynamics ...........................273 Applied Motion Products, Inc...........................274 Aurora Bearing Company.........275 Automation24, Inc. .....................276 AutomationDirect .......................277 Backer Hotwatt ...........................279 Bansbach Easylift ......................280 Bay Associates Wire Technologies ..........................281 Beckhoff Automation ...............282 Bel Power Systems (BPS) ........283 Beswick Engineering ................284 binder USA ...................................285 Bird Precision ...............................286 Bishop Wisecarver .....................287 Bodine Electric Company ........288 Boker’s Inc. ....................................289 Bosch Rexroth .............................290 BRECOflex Co., LLC ...................291 Brennan Industries ....................292 Brother Gearmotors ..................293 C-Flex Bearing .............................294 Cadence, Inc. ...............................295 Canfield Connector ...................296 Carlo Gavazzi ...............................297 Carlyle Johnson ..........................298 CC-LINK PARTNER ASSOCIATION ........................299 Central Semiconductor ............300 Centritec Seals ............................301 Century Spring ............................302 CGI Motion ....................................303 Chieftek Precision Co., Ltd. .....304 CIT Relay & Switch .....................305 Clippard .........................................306 CMT .................................................307 Cognex ...........................................308 Coilcraft ..........................................309 Components Corporation .......310 COMSOL ........................................311 CS Hyde Company .....................312 DATA IMAGE Corporation ........313 Data Modul Inc. ...........................314

Del-tron Precision, Inc. ..............315 Deublin ...........................................316 DieQua ...........................................317 Digi-Key Electronics ...................318 DMIC ................................................319 Dorner .............................................320 Eagle Stainless Tube ................321 Electrocube, Inc. .........................322 Emerson ........................................323 Emerson ........................................324 Encoder Products Company .................................325 Equipto Electronics ...................326 EXAIR Corporation .....................327 Fabco-Air .......................................328 Festo ...............................................329 Fischer Connectors ...................330 Flow Ezy Filters, Inc ...................331 FluiDyne Fluid Power ................332 Fotofab ..........................................333 GAM .................................................334 Gefran ............................................335 Groschopp ....................................336 Harmonic Drive LLC ...................337 HARTING, Inc. of North America.........................338 Harwin ............................................339 HAWE Hydraulik ..........................340 HBM, Inc. ........................................341 HEIDENHAIN CORPORATION ......................342 HELUKABEL USA .......................343 Helwig Carbon .............................344 HIWIN ..............................................345 Honeywell Intelligrated ............346 HYDAC International .................347 I-PEX Connectors .......................348 icotek Corp ....................................349 IDEC Corporation ........................350 IDS Imaging Development Systems GmbH .....................351 igus ..................................................352 IKO International, Inc .................353 Intech ..............................................354 Interroll ...........................................355 Interpower .....................................356 IronCAD ..........................................357 ITT Enidine ....................................358 J.W. Winco, Inc. ............................359 KEB AMERICA. Inc. .....................360 Keller America Inc .......................361 Key Bellevilles ..............................362 Keystone Electronics ................363 KHK USA Inc. ................................364 Koford Engineering ....................365 Kollmorgen ....................................366 Kuebler ...........................................367 Kuriyama of America .................368 LAPP USA .....................................369 Lee Spring .....................................370 LEMO USA, Inc. ...........................371 Lenze Americas ..........................372

Lin Engineering ...........................373 Madison Co. ..................................374 Main Manufacturing .................375 Maple Systems ...........................376 Master Bond ................................377 maxon precision motor .........................................378 MEAN WELL USA, Inc. ..............379 Memory Protection Devices, Inc. ............................380 METCASE ......................................381 MICROMO ......................................382 Miki Pulley US ..............................383 Mitsubishi Electric Automation, Inc. .....................384 mk North America, Inc. .............385 MOCAP ...........................................386 Motion Index Drives ..................387 MTS Sensors ................................388 Murrelektronik .............................389 MW Industries Atlantic Spring .......................390 MW Industries Bellows Tech ..........................391 MW Industries Helical ...............392 MW Industries ServoMeter .....393 Nason .............................................394 NB Corp ..........................................395 NBK America LLC ........................396 Neugart USA Corp. ....................397 New England Tubing Technologies ...........398 New England Wire Technologies ..........................399 Newark element14 ......................400 Newcomb Spring ........................401 Nitto Kohki USA .........................402 NKK Switches of America, Inc. ...........................403 Novotechnik .................................404 NSK Precision ..............................405 Ogura Industrial Corp. ..............406 OKW USA .......................................407 OMRON Industrial Automation .............................408 OMS Motion, Inc. .........................409 OPTO 22 ........................................410 Oriental Motor USA Corp. ........411 Orion Fans ....................................412 Panasonic Electric Components ..........................413 Parker Hannifin Corporation . Pneumatic Division ................... 414 PBC Linear ....................................415 PCB Piezotronics ........................416 Pelonis Technologies, Inc.........417 Pepperl + Fuchs ..........................418 PHD Inc. .........................................419 Pilz Automation Safety ............420 POSITAL-FRABA ..........................421 PRECI-DIP SA ...............................422 Prince Manufacturing ...............423

Protolabs .......................................424 Pyramid Incorporated ...............425 QC Conveyors ..............................426 R+W America ................................427 RelChip ...........................................428 Renishaw .......................................429 Rittal ................................................430 Rolec ...............................................431 Rollon ..............................................432 ROSS Controls .............................433 Rota Engineering .......................434 Rotor Clip .......................................435 RYCO Hydraulics .........................436 Sager Electronics .......................437 Schmersal .....................................438 Schneeberger, Inc. .....................439 Schneider Electric IMS .............440 Schroeder Industries ................441 SDP/SI-Stock Drive Product ....442 Serapid Inc ....................................443 Servo Kinetics ..............................444 SEW Eurodrive ............................445 SICK, Inc .........................................446 Siemens Industry, Inc. ..............447 Siemens PLM Software ............448 SIKO Products ..............................449 Smalley Steel Ring .....................450 Smart Products USA .................451 SMC Corporation of America ....................................452 SOLIDWORKS ...............................453 Sorbothane ..................................454 Spartan Scientific .......................455 STEUTE Industrial Controls.....456 Sunstone Circuits ......................457 Super Swivels ..............................458 Tadiran ...........................................459 Tech-Etch, Inc. .............................460 The Arthur G. Russell Co., Inc. .....................................278 The Lee Company .....................461 THK ..................................................462 Tolomatic .......................................463 Tompkins Industries ..................464 Tribal Manufacturing .................465 Trim-Lok, Inc. ................................466 US Tsubaki ....................................467 Veljan Hydrair ..............................468 WAGO .............................................469 Watlow ............................................470 Weintek USA, Inc. .......................471 Whittet-Higgins ...........................472 Wittenstein ...................................473 Xcentric Mold & Engineering ............................474 Yaskawa America, Inc. ..............475 Zero-Max, Inc. ..............................476

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DESIGN WORLD JANUARY 2019 - MAIN ISSUE  

Leadership in Engineering 2019

DESIGN WORLD JANUARY 2019 - MAIN ISSUE  

Leadership in Engineering 2019

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